Analytical and Finite Element Analysis of Hydroforming Deep Drawing Process

Authors: Maziar Ramezani, Thomas Neitzert

Abstract:

This paper gives an overview of a deep drawing process by pressurized liquid medium separated from the sheet by a rubber diaphragm. Hydroforming deep drawing processing of sheet metal parts provides a number of advantages over conventional techniques. It generally increases the depth to diameter ratio possible in cup drawing and minimizes the thickness variation of the drawn cup. To explore the deformation mechanism, analytical and numerical simulations are used for analyzing the drawing process of an AA6061-T4 blank. The effects of key process parameters such as coefficient of friction, initial thickness of the blank and radius between cup wall and flange are investigated analytically and numerically. The simulated results were in good agreement with the results of the analytical model. According to finite element simulations, the hydroforming deep drawing method provides a more uniform thickness distribution compared to conventional deep drawing and decreases the risk of tearing during the process.

Keywords: Deep drawing, Hydroforming, Rubber diaphragm

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1081075

References:

[1] Thiruvarudchelvan, S. and Travis, F.W. (2003) Hydraulic-pressureenhanced cup-drawing processes - An appraisal. Journal of Materials Processing Technology 140 (1-3 SPEC.), pp. 70-75.
[2] Ramezani, M. and Ripin, Z.M. (2012) Rubber-pad forming processes: technology and applications. Woodhead Publishing Ltd, ISBN-13: 978- 0857090942, UK.
[3] Fukui, S., Yoshida, K. and Abe, K. (1958) Deep drawing of cylindrical shell according to the so-called hydroform method. Japan Aerospace Exploration Agency, Report No. 333, 24(4), 77-98.
[4] Yossifon, S. and Tirosh, J. (1988) On the Permissible Fluid-Pressure Path in Hydroforming Deep Drawing ProcessesÔÇöAnalysis of Failures and Experiments. Journal of Engineering for Industry 110 (2), pp. 146- 152.
[5] Thiruvarudchelvan, S. and Lewis, W. (1999) Note on hydroforming with constant fluid pressure. Journal of Materials Processing Technology 88 (1), pp. 51-56.
[6] Vollertsen, F., Breede, R. and Lange, K. (1999) Method for deep drawing with multiple elastomer membranes. CIRP Annals - Manufacturing Technology 48 (1), pp. 221-226.
[7] Kandil, A. (2003) An experimental study of hydroforming deep drawing. Journal of Materials Processing Technology 134 (1), pp. 70-80.
[8] Lang, L., Danckert, J. and Nielsen, K.B. (2004) Investigation into hydrodynamic deep drawing assisted by radial pressure: Part I. Experimental observations of the forming process of aluminum alloy. Journal of Materials Processing Technology 148 (1), pp. 119-131.
[9] Lang, L., Danckert, J. and Nielsen, K.B. (2005) Investigation into hydrodynamic deep drawing assisted by radial pressure: Part II. Numerical analysis of the drawing mechanism and the process parameters. Journal of Materials Processing Technology 166 (1), pp. 150-161.
[10] Djavanroodi, F. and Derogar, A. (2010) Experimental and numerical evaluation of forming limit diagram for Ti6Al4V titanium and Al6061- T6 aluminum alloys sheets. Materials and Design 31 (10), pp. 4866- 4875.
[11] Chang, D. F. and Wang, J.E. (1998) Analysis of draw-redraw processes. International Journal of Mechanical Sciences 40 (8), pp. 793-804.
[12] Morovvati, M.R., Mollaei-Dariani, B. and Asadian-Ardakani, M.H. (2010) A theoretical, numerical, and experimental investigation of plastic wrinkling of circular two-layer sheet metal in the deep drawing. Journal of Materials Processing Technology 210 (13), pp. 1738-1747.
[13] Mielnik, E.K. (1991) Metalworking Science and Engineering. McGraw- Hill, New York, ISBN: 0-07-041904-3.
[14] Ramezani, M., Ripin, Z.M. and Ahmad, R. (2009) Computer aided modelling of friction in rubber-pad forming process. Journal of Materials Processing Technology 209 (10), pp. 4925-4934.
[15] Ogden, R.W. (1972) Large deformation isotropic elasticity-on the correlation of theory and experiment for incompressible rubberlike solids. Proceedings of the Royal Society of London, Part A 326, pp. 565-84.
[16] Ramezani, M. and Ripin, Z.M. (2010) Combined experimental and numerical analysis of bulge test at high strain rates using split Hopkinson pressure bar apparatus. Journal of Materials Processing Technology 210 (8), pp. 1061-1069.
[17] Panknin, W. and Mulhauser, W. (1957) Principles of the hydroform process, Mitt. Forschung. Blechver. 24, pp. 269-277.