Finite Element Analysis
of Multi Stage Deep
Drawing Process
By//
Hussien Ali Salman
Supervised by//
Dr.Waleed Al-Samaraey
Aims of Research:• This research aims to study the multi stage
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deep drawing process of cylindrical cup
(three stage) experimentally and
numerically and compare the result (force,
thickness, strain and stress distribution).
The numerical model is proposed for the
design of deep drawing process (3D
Model) by using finite element
analysis(ANSAS13).
In the second and third stage of drawing,
three direct re-drawing methods is use
(without blank holder, using centering
block method, and by using internal blank
holder).
• Study the effect of some parameter like, die profile
radius, material properties, and the degree of
ironing in the second and third stage on the
produced cup.
• Study the some defects which appear in
produce cups like wrinkling, and earring.
• In most papers which deals with the
redrawing process, taken the properties of
material (yield strength and strain hardening)
as constant, therefore i will measure this
properties and change them in each stage.
• I will may be doing compare between direct
and inverse redrawing process, and may be
doing redrawing of another cups (rectangular,
elliptical, polygon).
The three stage of drawing
First draw
Second draw without blank holder
Second draw with sleeve
Second draw with blank holder
Third stage with out blank holder
Third stage with sleeve
Third stage with blank holder
Some new paper
which deals with
the redrawing
process
((Research of numerical simulation in two pass deep
drawing forming 0f sheet metal ”Zhiren Han, Fuxia
Fan”2001”))
• This paper is proposed new numerical
simulation method of multi stage deep
drawing, this simulation simplified steps of
two pass stamping forming.
• Result show that this new method is
effective and successful in simulating two
pass deep drawing forming and the
simulation results are more reasonable.
((FEA-aid design of multi-stage drawing process and
tooling for production of a miniature sheet metal
component ”L.C.Chan, M.W.Fu”2009”)).
• This paper presents the design of multi stage
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drawing process and tooling aided by finite
element analysis (FEA).
A four stage drawing process and a set of four
station tooling are design.
The pre-designed process is then analyzed by
simulation, and the deformation behavior and
formability in each stage is revealed.
The reasonable drawing ratio and drawing depth
in each drawing operation are determined.
• The experiment is realized, and the
simulation and experiment are found to
have good agreement.
• The research further demonstates that
the FEA simulation can be used as an
effective tool to aid design of metal
formed component.
((APPLICATION ORIENTED OPTIMISATION OF SUBSEQUENT
REDRAW PROCESSES FOR CIRCULAR CONTAINERS” Géza T.
Nagy and Johannes Mulder”2008’)).
• A redraw model, was developed and validated for polymer
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coated sheets. The requirement for accuracy was to be
able to feed the resulting cup into further models of the
subsequent redraw stages, and eventually.
In a subsequent cupping process, besides prediction of
stresses and strains, the wall thickness profile has to be
predicted with high accuracy.
A wide range of parameter studies were performed during
development and validation to find and optimize the most
significant parameters among material properties of the
polymer layer.
The model is now capable to predict average cup height
and wall thickness profile in rolling direction within a
remarkable 3% accuracy, and the stresses and strains
present within the material.
It is also possible to predict the level of shearing within
the polymer layer which may lead to angel hair formation
during manufacture.
(EXPERIMENTAL INVESTIGATIONS OF EFFECTS OF PVD – COATED TOOLS ON
QUALITATIVE AND QUANTITATIVE OUT-PUT FORCES AND PRESS WORK IN
DRAWING AND REDRAWING ALUMINIUM AND LOW CARBON STEEL
WORKMATERIALS INTO A CUP-LIKE SHAPES” Jaromír Audy’2009’).
• The aim of this paper was to study the effect of TiN (PVD) and
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TiAlN (PVD) coatings on the forces and press work when cup
forming (1200) aluminum and (1010) steel work materials.
The forming experiments were conducted (both in drawing and
redrawing, two stage) using the same type tools to study the
benefits of coating in cup forming press operations.
The results showed that patterns of forces and press work
produced by the uncoated and coated tools tested showed
qualitative agreement and quantitative differences at 95 and
greater confidence level.
The coated tools reduced drawing forces, on average, by 6% (for
steel) and 9% (for aluminum), and redrawing forces by 16% (for
steel) and 22% (for aluminum).
The press work was also reduced, on average, by 6% and 10% in
drawing and by 20% and 25% in redrawing the steel and
aluminum, respectively.
(An Investigation into the Different Hardening Models in
Reverse Forming of Thin Sheets” M. Kadkhodayan and
J.Mosayebi”2009”).
• This paper discusses a finite element analysis of the
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Bauschinger effect in the reverse cup drawing process.
In order to study the Bauschinger effect, several
hardening models are considered such as isotropic,
kinematic, and combined forms in the linear and
nonlinear cases.
The obtained results have been compared with some
experimental results reported in literature.
The various factors, namely, normalized stress, and the
punch forces, for both first and second stages have been
calculated for different materials and thicknesses.
Results show that the combined model had acceptable
agreement with the empirical data through both stages.
In this simulation, the predicted thickness distribution by
two models shows practically no difference. However the
resulting stresses and punch forces are quite different
(Experimental and numerical study of reverse re-drawing of
anisotropic sheet metals” S. Thuilliera,*, P.Y. Manacha”2002).
• This study deals with the experimental and numerical
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reverse re-drawing of cylindrical cups.
Experimental data consist of force–displacement curves
of the punch and thickness distribution in the cup wall at
0, 45 and 90 to the rolling direction (RD).
The drawing process was simulated using both the
dynamic explicit finite element code Pam-Stamp and the
static implicit home code DD3IMP.
Moreover, the occurrence of strain path changes during
the first and the second stage is also investigated in
order to estimate their influence.
An experimental investigation of the reverse re-drawing
of mild steel sheets have been performed.
(FINITE ELEMENT APPROACH TO ANALYSIS OF AXISYMMETRIC
REVERSE DRAWING PROCESS”Z. Keran et al.: FINITE
ELEMENT”2006’)
• The intention of this research is to make analyze of deep
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drawing Cr-Ni stainless steel process (forces, stress and its
behavior).
The results are taken from two sources and their
comparison is made. The first source of results are
experiments made on hydraulic press, and the other source
are results obtained by creation of finite element model
(FEM).
Data sheets and force diagrams present the results, and
material stress can be seen on figures that are result of the
simulation.
Experiments were made on double acting hydraulic press.
The double action refers to the clamping mechanism
moving independently of the punch mechanism.
This allows for the boundaries of the sheet blank to be
clamped while the punch pushes the sheet into the die
cavity.
((Designing of a Reconfigurable Set of inverse Re-Drawing Dies
Aided by FEM Simulation” C. Maier1, V. Tabacaru1”2007)).
• This paper deals with the methodology for developing a
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laboratory inverse redrawing device.
The drawing process is performed in two phases: a
direct drawing of a circular blank followed by a second
reverse re-drawing phase on the same device.
Finite element simulations are carried out in order to
define geometrical characteristics of the modular redrawing device and to estimate the punch force
evolution for different dimensions of punch, die and
blank holder and for a large class of materials.
These two stages must to be progressive in order to
avoid the errors due to the positioning of the piece
obtained in the first stage..
((Design of the virtual model of re-drawing process” C. Maier1,
Kosmalski N.”2007)).
• This paper deals with the develop the finite element
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modelization of the re-drawing process in order to create
his virtual model.
The main goal of this simulation is to define geometrical
parameters of the process, in order to design a reverse
re-drawing machine, and have the possibility in the
future to compare experimental results and finite
element results.
The second goal is the estimation of the blank reaction
(ability to support the process), and eliminate as well the
default obtain during the simulation.
The drawing process is performed in two phases: a
direct drawing of a circular blank followed by a second
reverse redrawing phase on the same device.
((Tool design in a multi-stage drawing and ironing process of a
rectangular cup with a large aspect ratio using finite element
analysis” Se-Ho Kim, Seung-Ho Kim, Hoon Huh “2002”)).
• Tool design is carried out for a multi-stage deep
drawing and ironing process of a rectangular cup with
the large aspect ratio using the result of the finite
element analysis.
• The analysis simulates the five-stage deep drawing and
ironing process with the thickness control of the cup
wall.
• The analysis reveals that the difference of the drawing
ratio within the cross section induces non-uniform
metal flow which causes severe local extension.
• The irregular contact condition between the blank and
the die also induces non-uniform metal flow which
causes local wrinkling.
• The original design is examined by the finite element
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analysis and the reason of the unfavorable result is
explained. Then, the modification guideline for the new
tool design is proposed according to the finite element
analysis result in order to lessen the possibility of failure
during the forming process.
The finite element analysis result with the improved tool
design confirms that the proposed design not only
reduces the possibility of failure but also improves the
quality of a deep-drawn product.
((A study of effect of physical vapour deposition coated tools
on the forces in deep drawing cylindrical cups from ferrous
and non ferrous materials ”Audy J.,Doyle D”2000” )).
• In this paper an investigation of PVD TiN coating on
forces, power and press work is detailed for drawing and
redrawing operations involved in a cup forming production.
Work materials used are (1010)steel and (1200) aluminum.
• Results showed that the coated tools reduced the drawing
forces by (9%) and redrawing forces by (22.5%) and the
drawing press work by (10%) and redrawing press work by
(25.5%) against uncoated tools when forming cups from
(1200) aluminum.
• The tools showed reductions in the drawing forces by
(6%) and redrawing forces by (16%) and drawing press by
(7%) and redrawing press work by (21%) against
uncoated tools when forming cups from (1010) steel work
material.
• Hence it was found that the benefit of coating appears to
be more significant in redrawing than drawing
((Process design for multi stage elliptical cup drawing with the
large aspect ratio ”Hoon Huh, Se-Ho Kim”2000” ))
• Finite analysis of multi stage deep drawing processes is
carried out for the tool shape design of the elliptic cup
drawing with the large aspect ratio.
• A multi stage inverse finite element scheme is
developed and applied to the complicated tool design
problem of three dimensions for rapid estimation of the
initial blank shape, thickness and the strain distribution.
• A direct finite element method is then carried out to
inspect the failure such as tearing and wrinkling during
forming more accurately.
• The deep drawing process of an elliptic cup with the
large aspect ratio consists of four deep drawing stages in
which the cylindrical cross section at the first stage of
drawing is changed to the elliptic shape gradually.
• Due to the difference of the drawing ratio between the
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major and minor axis, non-uniform metal flow is
expected to cause wrinkling and severe extension.
The irregular contact condition between the blank and
die also induces non uniform metal flow to cause tearing
and wrinkling.
The first and the second stage of the elliptic cup drawing
process are performed with the cylindrical punch to
impose uniform deformation while the third and the
fourth stage are performed with the elliptic punch to
form the desired shape.
((design modification in a multi stage rectangular cup drawing
process with the large aspect ratio by an Elasto-plastic Finite
Element Analysis ”Se-Ho kim, Hoon Huh”2002)).
• Finite element analysis of multi stage deep drawing
process is carried out for the process design of
rectangular cup with the large aspect ratio.
• Simulation is performed for investigation of the failure
such as tearing and wrinkling during forming process.
• The analysis reveals that the difference of the drawing
ratio within the cross section produce non uniform metal
flow to cause wrinkling and severe extension. The
irregular contact condition between the blank and the
die also induces non uniform metal flow.
• This paper identifies such unfavorable mechanism in the
rectangular cup drawing and proposes the modification
guideline in the design of the process and the tool
shape.
• The analysis is concerned with the six stage deep
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drawing process of a rectangular cup with the large
aspect ratio.
Then, the modification guideline is proposed with the
finite element analysis result in order to eliminate failure
during the forming process.