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This work aims to study the effect of the blank holder force on strains and thickness distribution along cup wall of drawn part in deep drawing process. 2-D model of cylindrical cup of (40mm) outer diameter, and (0.5mm) thickness made from low carbon steel (1008–AISI), has been developed. A commercially available finite element package (ANSYS14.0) was used to perform the numerical simulation of deep drawing process. The experimental work carried out using digital image processing technique. Five values of blank holder force =5, 7.5, 10, 12, 15 KN) were adopted. The numerical results of this model were compared with experimental results and the results show that, the value of the thickness and hoop strain at cup rim decrease with increasing blank holder force, while radial strain increases with increasing blank holder force. The best thickness distribution over all zones in produced cup obtained when using blank holder force with value =10 KN).

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The aim of this paper is to design and fabricate a star die and a cylindrical die to produce a star shape by redrawing the cylindrical shape and comparing it to the conventional method of producing a star cup drawn from the circular blank sheet using experimental (EXP) and finite element simulation (FES). The redrawing and drawing process was done to produce a star cup with the dimension of (41.5 × 34.69mm), and (30 mm). The finite element model is performed via mechanical APDL ANSYS18.0 to modulate the redrawing and drawing operation. The results of finite element analysis were compared with the experimental results and it is found that the maximum punch force (39.12KN) recorded with the production of a star shape drawn from the circular blank sheet when comparing the punch force (32.33 KN) recorded when redrawing the cylindrical shape into a star shape. This is due to the exposure of the cup produced drawn from the blank to the highest tensile stress. The highest value of the effective stress (709MPa) and effective strain (0.751) recorded with the star shape drawn from a circular blank sheet. The maximum value of lamination (8.707%) is recorded at the cup curling (the concave area) with the first method compared to the maximum value of lamination (5.822%) recorded at the cup curling (the concave area) with the second method because of this exposure to the highest concentration of stresses. The best distribution of thickness, strains, and stresses when producing a star shape by redrawing the cylindrical shape into a star shape

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Lightweight materials is used in the sheet metal hydroforming process, because it can be adapted to the manufacturing of complex structural components into a single body with high structural stiffness. Sheet hydroforming has been successfully developed in industry such as in the manufacturing of the components of automotive.The aim of this study is to simulate the experimental results ( such as the amount of pressure required to hydroforming process, stresses, and strains distribution) with results of finite element analyses (FEA) (ANSYS 11) for aluminum alloy (AA5652) sheets with thickness (1.2mm) before heat treatment (BHT) and after heat treatment (AHT) respectively in the circular die with cavity equals to (20mm) . The comparison of results by these two approaches show the same tendency that an improvement formability, also the plastic deformation is greatly enhanced AHT for same metal.

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The main aim of this work is design and manufacturing cylindrical and hexagonal dies to produce hexagonal cups from transform the cylindrical cups to hexagonal cups and affect of wall corner radii of die. As well as using some parameters which effect of on the hexagonal deep drawing process, especially on the punch force, strain distribution and variation of the cup wall thickness for three stages such as (wall corner radius of die and punch speed). 3-D models of cylindrical cups of (43 mm) outer diameter, and diagonal and side distance of hexagonal cups are (41and36mm) respectively, (0.7mm) thickness made from low carbon steel (1006–AISI), has been produced. A commercially available finite element program code (ANSYS11.0), was used to perform the numerical simulation of deep drawing operation. Two types of wall corner radii of die ( =0.7, 4 mm) with constant punch profile radius equal to ( =4) mm and die profile radius equal to ( =8 mm), various drawing speeds equal to (50, 200, and 500 mm/min (were used. From the numerical and experimental results of drawing operation, it, the maximum thinning occurs at cup corner radius when used wall corner radius of die equal to ( = 0.7mm). The best strain and thickness distribution over all zones in produced cup obtained when using wall corner radius of die is equal to = 4 mm) and High drawing speed (v=500 mm/min) leads to increase drawing force and more thinning in cup corner.

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The main aim of this work is to produce hexagonal cup drawn from flat sheet (blank Ø80) and effect of wall corner radii of die on drawing process. The dimension of diagonal and side hexagonal cup are (41,36mm) and (36 mm) respectively, and (0.7mm) thickness made from low carbon steel (1006–AISI), has been produced. A commercially available finite element program code (ANSYS11.0), was used to perform the numerical simulation of drawing operation. Two types of wall corner radii of die ( =0.7, 4 mm) with constant punch profile radius equal to ( =4) mm and die profile radius equal to ( =8 mm (were used to investigate the effect of die corner radius on punch force, variation of cup wall thickness and the strain distribution over the cup wall. The numerical results of this model were compared with experimental results and the results show that, the greatest thinning occurs when used wall corner radius of die equal to ( = 0.7mm) due to great stretching of the metal over the corner radius. The best strain and thickness distribution over all zones in produced cup obtained when using wall corner radius of die is equal to = 4 mm).

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