Numerical and Experimental Investigation of Deep Drawing Process of Square Cross-Section Cups Made of St۳۷ Without Blank Holder

Conical dies without blank holders are an interesting subject for metal-forming applications because of their structural simplicity and reduced tooling complexity. However, reduced control of material flow and the increase likelihood of defects, such as excessive thinning and shrinkage, are the main limitations of this process. Therefore, proposing an optimum angle to mitigate this limitation is essential. In this study, the effects of the die half-cone angle and drawing ratio on the thickness distribution and equivalent plastic strain during the deep drawing of a square cup were investigated numerically and experimentally. A statistical study using a full factorial design was employed to examine various combinations of die half -cone angles and drawing ratios. Using this method, the combined effect of the die angle and yield drawing ratio on the thickness distribution and plastic strain was investigated. Despite previous studies suggesting a die with an ۱۸° angle, the results showed that reducing the angle to ۱۶° led to a more uniform thickness distribution and a lower maximum equivalent plastic strain. Specifically, at a drawing ratio of ۱.۸۷, the use of a ۱۶° die angle resulted in a ۲۸% reduction in thinning and a ۱۴% reduction in thickening compared with the ۱۸° die angle.

کلیدواژه ها:

Sheet metal forming ، Square cross section ، Conical die ، Deep drawing without blank holder