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Article
Experimental and Theoretical Study of Square Deep Drawing

Authors: Karem Muhsin Younis --- Adil Shbeeb Jaber
Journal: Engineering and Technology Journal مجلة الهندسة والتكنولوجيا ISSN: 16816900 24120758 Year: 2011 Volume: 29 Issue: 12 Pages: 2456-2467
Publisher: University of Technology الجامعة التكنولوجية

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Abstract

This work aim to study the effect of process parameters used in square deepdrawing operation such as ; die and punch profile radius, blank size, blank shape, onproduced cup wall thickness, strain distribution across the wall of the drawn part,punch force, earing shape and height of the drawn cup. 3-D model of square cup(41.4mm by 41.4mm), and 0.7 mm thickness from Low carbon steel (AISI 1008), hasbeen developed. Because of the symmetry in the specimen geometry, only one fourthportion of the model was needed to be analyzed using finite element method, acommercial available finite element program code (ANSYS 11), is used to performthe numerical simulation of the deep drawing operation, and the numerical results ofearing shape were compared with the experimental work. In this work, three types ofblank shape (circular, square, and octagonal), with different sizes, four types of punchprofile radii of 3, 5, 6, and 7mm and three types of die profile radii of 3, 5, 7mm havebeen chosen to form a square cup. The results show that, excessive earing will appearin the square cup when square blank was used, due to excessive material in the cornerand minimum material in the flat side, and when using octagonal blank which have anequivalent surface area to the square blank, the earing in the cup corner is reducedbecause of extraction of the excessive material from the corner of the blank. The bestresults were obtained from the circular blank, according to useful drawing height andearing.


Article
Experimental Evaluation and Finite Element Simulation to Produce Square Cup by Deep Drawing Process
بحث عملي و المحاكاة بالعناصر المحدد لإنتاج وعاء مربع بواسطة عملية السحب العميق

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Abstract

Deep drawing process to produce square cup is very complex process due to a lot of process parameters which control on this process, therefore associated with it many of defects such as earing, wrinkling and fracture. Study of the effect of some process parameters to determine the values of these parameters which give the best result, the distributions for the thickness and depths of the cup were used to estimate the effect of the parameters on the cup numerically, in addition to experimental verification just to the conditions which give the best numerical predictions in order to reduce the time, efforts and costs for producing square cup with less defects experimentally is the aim of this study. The numerical analysis is used to study the effect of some parameters such as die profile radius, radial clearance between die and punch, blank diameter on the length and thickness distributions on the cup, dynamic-explicit (ANSYS11) code based on finite element method is utilized to simulate the square deep drawing operation. Experiments were done for comparison and verification the numerical predictions. effective square cup with less defects and acceptable thickness distributions were produced in this study. It is concluded the most thinning appear in the corner cup due to excessive stretching occur in this region and also it is found the cup thickness and height prediction by numerical analysis and in general in harmony with experimental analysis.

عملية السحب العميق المستخدمة لإنتاج أوعية المربعة الشكل هو عملية جدا معقدة وتسيطر عليه الكثير من المتغيرات وبالتالي ترافقها الكثير من العيوب مثل التاذن والتجاعيد والكسر في الأواني الناتجة. دراسة تأثير بعض من هذه المتغيرات العملية لتحديد قيم هذه المتغيرات التي تعطي أفضل النتائج , حيث تم الاعتماد على توزيع السمك والأعماق لوعاء المنتج لغرض دراسة تأثير هذا المتغيرات عدديا, إضافة إلى الإثبات التجريبي الظروف التي تعطي أفضل التنبؤات العددية فقط لغرض تقليل الجهود والوقت والكلفة لإنتاج وعاء مربع خالي من العيوب تجريبا هو هدف هذا البحث. دراسة عددية استخدمت لدراسة تأثير بعض المتغيرات من نص قطر تقوس القالب والخلوص بين القالب والخرامة و قطر الغفل على ارتفاع الوعاء و توزيع السمك على طول الوعاء المسحوب, برنامج Ansys المعتمد على طريقة العناصر المحددة استخدم لإجراء المحاكاة لعملية السحب العميق المربع. تجارب عملية استخدمت لمقارنة واثبات النتائج التي تم الحصول عليها من المحاكاة العددية. وعاء مربع خالي من العيوب تم إنتاجه مع توزيع مقبول السمك على طول الوعاء,وقد تم استنتاج ان الترقق غالبا ما يظهر عند زاوية الوعاء نتيجة للتشوهات القاسية في هذا المنطقة و وقد وجد أيضا توافق بين نتائج التنبؤات العددية لتوزيع السمك والارتفاعات والتجارب العملية.


Article
Experimental and Numerical Study of the Earing Defect During Square Deep Drawing Process

Authors: Kariem M. Younis --- Adil Sh. Jaber
Journal: Engineering and Technology Journal مجلة الهندسة والتكنولوجيا ISSN: 16816900 24120758 Year: 2018 Volume: 36 Issue: 12 Part (A) Engineering Pages: 1267-1275
Publisher: University of Technology الجامعة التكنولوجية

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Abstract

Deep drawing process is a very complex process which controls a lotof parameters and the associated defects. The aims of this research are to discussthe effect of parameters of the process utilized in square deep drawing processsuch ; material properties, blank size, blank shape on the height and shape ofearing defect appear of the drawn cup. Three dimensions model from low carbonsteel (AISI 1008) with thickness 0.7mm of square cup (41.4mm by 41.4mm).The finite element software (ANSYS 11) was utilized to carry out the numericalsimulation of the deep drawing process, and the experimental work result ofearing was compared with numerical of earing shape result. In this work, threetypes of the radius of die entry of 3, 5, 7mm, three shapes of the blank (circular,octagonal, and square) with various diameters, four types of radius of the punchprofile of 3, 5, 6, and 7mm had been selected to form a cup with square sides.The results show that, The circular blank give the best results according to earingdefect and useful height of the drawn cup, when square shape of blanks wereutilized, excessive earing will show in the square cup, due to non-uniformdistribution of blank material around the perimeter of the die cavity, minimummaterial in the flat side and too much material found in the die corner, whilewhen using octagonal shape of blanks which have a same surface area to thesquare blank, the earing will reduce in the corner of the cup due to extract of thetoo much material from the blank corners. The results showed a high agreementbetween the experimental work and numerical simulation reached to 85 % interms of the shapes and lengths of the earing appearing in the square cups.


Article
Metal Flow Control in Producing the Non Symmetrical Parts in Deep Drawing Process

Authors: Kariem M. Younis --- Adil SH. Jaber
Journal: Engineering and Technology Journal مجلة الهندسة والتكنولوجيا ISSN: 16816900 24120758 Year: 2018 Volume: 36 Issue: 6 Part (A) Engineering Pages: 603-611
Publisher: University of Technology الجامعة التكنولوجية

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Abstract

the quality of the cups drawn in the deep drawing process are secured by the rate of metal flow into the die cavity, efficiently control on the metal flow can reduce and eliminate a lot of defects such as wrinkling, tearing and earing especially in the square deep drawing due to the non-uniform stresses induced along die cavity. This control is obtained using a restraining force supplied by blank holder tool or draw beads or both. Therefore this research focuses on the study these parameters numerically and experimentally. Ansys software based on finite element method was used to model and analyze the influence of blank holder gap and draw bead parameters in the forming process. Appropriate number of the experiments were done to compare and verify the results obtained in the numerical simulation.

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