Formability Analysis of Deep drawing Process by Finite Element Simulation
Anup S. Atal, M. T. Shete
Majority of automobile and appliances components are made by deep drawing sheet metal process. So these growing need demands a new design methodology based on metal forming simulation. With the help of metal forming simulation we can identify the problem areas and solutions can be validated in computers without any expansive shop floor operations prior to any tool construction. Metal forming simulation is also helpful at the product and tool design stage to decide various parameters. Optimization of process parameters in sheet metal forming is an important task to reduce tryout and manufacturing cost. To determine the optimum values of the process parameters; it is essential to find their influence on the deformation behavior of the sheet metal. The finite element simulation analysis is carried out to predict the effect of parameters on formability using various finite element simulation software available. In the present work formability analysis is carried out for gear cover by varying parameters like blank holding force; friction coefficient and blank size using Altair HyperForm; LS-DYNA predictive tool. Various iterations are performed and from result thickness variation and strain generated from forming limit diagram are analyzed. The die; punch; binder and blank are the main components developed as virtual tryout set. A constant blank holder force strategy was applied and the results were compared for various blank holder force values along with other parameters used.
Keywords: Finite Element Analysis, Deep drawing, simulation
Edition: Volume 3 Issue 6, June 2014
Pages: 2153 - 2156