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Effect of Die Radius on Blank Holder Force and Drawing

Ratio: A Model and Experimental Investigation
a b b
S. Sezek , V. Savas & B. Aksakal
a
Ataturk University, Vocational School of Askale , Erzurum, Turkey
b
Faculty of Technical Education, Department of Mechanical Education , Firat University ,
Elaz, Turkey
Published online: 05 Aug 2010.

To cite this article: S. Sezek , V. Savas & B. Aksakal (2010) Effect of Die Radius on Blank Holder Force and Drawing
Ratio: A Model and Experimental Investigation, Materials and Manufacturing Processes, 25:7, 557-564, DOI:
10.1080/10426910903365729

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 Materials and Manufacturing Processes, 25: 557564, 2010
Copyright Taylor & Francis Group, LLC
ISSN: 1042-6914 print/1532-2475 online
DOI: 10.1080/10426910903365729

Effect of Die Radius on Blank Holder Force and Drawing

Ratio: A Model and Experimental Investigation
S. Sezek1 , V. Savas2 , and B. Aksakal2
1
Ataturk University, Vocational School of Askale, Erzurum, Turkey
2
Faculty of Technical Education, Department of Mechanical Education, Firat University, Elazg, Turkey

A numerical model for a newly designed deep drawing process has been built up and analyzed using the nite element method (FEM) in
comparison with performed experiments using the DIN 10130-99-DC05 sheet material. It was aimed to increase the limiting drawing ratio (
)
and decrease the blank holder forces (BHFs). To predict the deformation behavior of the process, the parameters are analyzed using FEM. The
effects of the die radius, blank holder and punch forces, friction, cup wall, and blank thickness in the process were investigated. A deep drawing
die set was designed and manufactured, and the validity of the design was demonstrated through the theoretical and experimental analysis. The
results showed that the blank holder die radii and friction have the greatest effect on the thickness of deformed steel cups. The drawing ratio of
Downloaded by [Purdue University] at 18:23 01 September 2014

has an inuence on the BHFs and it decreased with increasing die angle (). The
was considerably increased by 26% compared with dies
having no angle ( = 0
). The current design and analyses can help the optimization of the control scheme of drawing processes rather than using
the conventional designs. A comparison of the predicted and experimental results showed good agreement.

Keywords BHF; Deep drawing; Metal forming BHF.

Introduction prepared to investigate depths, tearing and wall thickness

Deep drawing is an important process used for producing
cups from sheet metal in large quantities, which are
affected by many process variables such as the blank
shape, proles and radii of the punch and die, friction,
the blank holder force (BHF), and the formability of the
materials. The deviation of these parameters under the
optimized conditions is closely related to the sensitivity in
the deep drawing process. When the above parameters are
determined by trial and error, an increase in production
time and, therefore, a high cost occur. Therefore, practically
obtaining the values pertaining to the material to be
processed will provide advantages for manufacturing and
production costs.
The inuence of several numerical parameters on the
predicted punch force and earing prole has been analyzed
[1]. The nite element method was employed in conjunction
with the adductive network to predict the optimum blank
contour of an elliptic cylindrical cup with ear-less in deep
drawing. A nite element-based code was also utilized to
investigate the material ow characteristics under different
process parameters, thus establishing a predictive model
[2]. In another investigation, the nite element simulations
were carried out to determine the formability characteristics
of aluminum steel tailor welded blanks [3]. A hydro-
mechanical deep drawing system has been prepared and
the inuence in forming the BHF has been investigated
using AA5754-O [4]. An experimental system has been
Received June 26, 2009; Accepted August 8, 2009
Address correspondence to B. Aksakal, Faculty of Technical Education,
Department of Mechanical Education, Firat University, Elazg 23119,
Turkey; E-mail: b.aksakal@rat.edu.tr
557
variations of aluminum square cups; the numerical results
were compared and the best forming conditions were
proposed [5]. A die set with a maximum deep drawing ratio
for a punch diameter of 100 mm has been designed and
constructed [6]. The signicance of the process parameters
on the deep drawing characteristics of a stainless steel
cup was determined only theoretically [7]. An efcient
damage model coupling of both anisotropic elasto-plasticity
and isotropic ductile damage was achieved using an
ABAQUS nite element code [8]. The inuence of the
initial anisotropy in achieving an optimal blank shape was
analyzed using anisotropic mild steel and nearly isotropic
dual-phase steel blanks for different tool geometries [9].
There have been many attempts to predict the initial blank
shape for minimizing the earing. The metal ow was
analyzed and the deformation divided into sub-zones by
proposing a velocity eld for each zone [10]. In a work
on a rectangular conventional cup drawing for the straight
cup side, both the experimental and the FEM simulation
results showed that the higher radial stress occurred at the
upper tangential point of the punch [11]. Two failure criteria
were developed based on the effective strain and failure
parameters and both were formulated as a function of the
ZenerHolloman parameter [12].
In deep drawing, as the blank is radially drawn inwards,
the ange undergoes radial tension and circumferential
compression. The latter may cause wrinkling of the ange
if the drawing ratio is large or if the cup diameter-to-
thickness ratio is high and the radial tensile stress on the
cup wall is induced by the punch force. Hence, when
the cups are drawn at larger drawing ratios, larger radial
tensions are created on the ange and higher tensile
stress is therefore needed on the cup wall. As tensile
 558
stress on the cup wall is limited to the ultimate tensile
strength of the material, it is possible to limit the drawing
ratio and to draw deeper cups, recourse being made to
special drawing processes such as hydro-forming, hydro-
mechanical forming, counter-pressure [13], and hydraulic-
pressure-augmented deep drawing [14]. These processes
are relatively slow compared with the deep drawing or
redrawing process and the drawing ratios are limited to
3.5 or 4 at most. However, a conventionally drawn cup
can be redrawn twice or more to obtain drawing ratios
of the order of 5, 6, or even larger values. A few more
theoretical and experimental works also exists by using
conventional die sets [15, 16]. It is important in such a
process to decrease the (BHFs) and this is only possible
with new designs and by optimizing the process parameters.
Doege and Sommer [17] rst examined the possibility of
controlling the BHF with respect to the displacement of the
punch as a means of safely avoiding the onset of either
wrinkling or tearing. Hardt and Lee [18] established a BHF
system to maintain a constant blank holder displacement
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allowing a limited amount of ange wrinkling. Hardt
et al. [19] employed a real-time closed-loop control of
sheet forming operations to determine the optimal BHF
trajectories. Many other researchers have conducted similar
experiments based on the area of BHF, which have been
reviewed and experimentally tested [20, 21].
During the deep drawing process, the blank is likely
to develop defects if the process parameters are not
optimized and selected properly. Optimization of the
process parameters, such as the die radius, BHF, friction
coefcient, etc., can be accomplished based on their degree
of importance in the sheet metal forming characteristics. The
previous studies performed on deep drawing were mostly
focused on investigating the process parameters using the
conventional punch-die designs. In this study, however,
it was aimed to increase the deep drawing ratio and decrease
the BHFs to increase the forming limits by using a new
type of deep drawing die sets. The validity of the developed
design was demonstrated experimentally and theoretically.
The drawing ratio was increased, and the BHFs were
decreased by using the current drawing die design. The
stress distributions for different deformation rates, frictions,
blank holder radii, and blank holder angles have been
demonstrated.
Materials and methods
Material
In this study, DIN 10130-99-DC05 steel blank with high
formability and having a thickness of 1 mm was used.
Tensile tests were carried out in rolling directions of 0
,
45
, and 90
and with 2 mm/min of tension speed using a
tensile test machine (Shimadzu-100 kN) and the results are
given in Table 1.
Experimental Procedure
The experiments have been carried out using a 60 kN
hydraulic press with a die cushion to control the BHF and
limit the switch to determine a stroke of upper ram at a
xed punch velocity of 4 mm/s. A punch with a diameter
of 46 mm and a die diameter of 48.5 mm is used with a
S. SEZEK ET AL.
Table 1.The mechanical properties of the
test material.
Angles of roll Yield strength Tensile strength
directions (MPa) (MPa)
0
287.4 389.5
45
295.3 405.6
90
299.1 314.8
Average 293.93 369.96
1.15 mm of clearance. The deep drawing characteristics of
the blank have been tested experimentally by using the
designed and manufactured die set. The punch force and
stroke have been measured with devices attached to the
press counter. Figure 1 shows the new type of deep drawing
die set used in this study, which promises to be a better
design compared with conventional ones.
The punch prole radius (Rp) was kept constant at 10 mm
and the die corner radius (Rm ) was xed at 8 mm; the punch
velocity was also kept constant at 4 mm/s. To investigate
the effect of punch and BH forces, a load cell (Pan Cake
load cell, 20 tons) coupled with a PC was settled under
the die. The BHF was applied to the blank, and then the
punch was moved into the die hole. The deep drawn cup
was then removed using the spring-back force. The deep
drawn cup has been cut vertically, starting from the top
to the bottom; the wall thicknesses were measured using a
micrometer with a sensitivity of 103 .
The Deep Drawing Model
The deep drawing process was modeled using the
Autocad-2007, and then the parts were converted into an
(stl) le and were transferred into the Femutech subprogram.
The meshing and 3D FEM modeling were established
for the parts and 15,000 tetragonal elements were used
in the meshing as each length of the element was 0.01 m.
Since severe mesh distortions occurred during the plastic
deformation, the rene meshing option was adjusted to the
open position, allowing the program to run. Such rening
was used especially for the zones in the specimens that were
likely to undergo excessive plastic deformation, and so this
enabled us to calculate the stress distribution with respect to
the applied deformation rates. A contact element (2D) was
constructed for the contacts between the workpiece and dies.
Figure 1.The newly designed and manufactured deep drawing setup.
 EFFECT OF DIE RADIUS
The re-meshing process was applied to the parts where the
route of the workpiece undergoes the plastic deformation
and contacts the dies. The established program was then run
and took 2 hours for each deep drawing cycle on a 2GHz
Core Duo Intel Centrino PC.
Results and discussion
The quality of the drawn part depends on the forming
conditions, and the optimal value of process parameters
and their favorable combination is important for the deep
drawing process. In order to show the advantages of a
new design, the process parameters, such as BHF, friction,
punch and die radii, in addition to the mechanical properties,
the cup wall thickness of the sheet metal, and the parts
geometry have to be analyzed before the actual process.
Fractures and wrinkles are the major modes of failure in
sheet metal processes. Hence, using the proper BHF is
an essential criterion to restrict the wrinkling tendency
and so avoid tearing of the drawn cup. During a deep
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drawing operation, the workpiece is subjected to radial and
compressive stress that is normal to the element due to the
blank holder pressure [8]. The smaller the BHF, the more
material will be drawn into the die cavity and participate
in a more homogenous deformation, thus there is a smaller
possibility of tearing. In order to fulll the desired drawing
height, the BHF should be kept as low as possible [22].
The BHF was predicted and measured experimentally with
respect to the angles of  and
, the die angle, friction, and
the punch stroke.
Figure 2 shows some experimental deep drawn cups (a),
for various
values and angles of  = 0
, 5
, 10
, and
15
, in comparison with predicted illustrations (b) provided
by the model. The inuence of the -angle on the BHF is
shown in Fig. 3 for a constant value of
= 175. It was
thought that if the -angle is applied in the die and blank
holder corners, this may cause a decrease in the BHF. This
is due to an easy ow of the blank into the die cavity by
decreasing the radial stresses. From the analyses, the BHF
decreased with an increasing -angle, and the correlation
between the experiments and the prediction is found to be
good. However, increasing the -angle caused an increase
in the axial force and this caused a decrease in the BHF. For
Figure 2.Comparison of experimental and theoretical (FEM) deep drawn samples: (a) experimental, (b) prediction of FEM.
559
Figure 3.Inuence of the die () angle on the BHFs.
example, while the BHF is 10362 N at the value of  = 0
,
it decreases to 3002 N at the value of  = 5
. The radial
forces decrease at the values of  = 15
and
= 220 as the
-angle is further increased. In this case, the -angle of the
die and blank holder will no longer be important because
the wrinkles are likely to occur eventually after those values
of  and
. The BHF has been impeding the wrinkle and, in
production processes, it is therefore preferred to have small
values. There is a slight difference between the experiment
and the model between the values of  = 5
and 15
. As
shown in Fig. 4, the
value has an inuence on the BHFs,
and the BHF decreased by increasing the
value and the
-angle.
Figure 5 shows the inuence of the -angle and friction
on the drawing ratio of
. The results show that the drawing
ratio of
increases slightly with an increasing -angle and
decreases with increasing friction. It is actually expected
that the higher frictions and lower -angles also lower the
punch stroke. Figure 6 shows the relationship between the
punch force and punch stroke by depending on the effect
of -angles in comparison with the experiments. The punch
force immediately rises with the punch stroke from 0 up
to 2535 mm as sufcient friction is present initially for
the slide and ow of the metal into the die cavity. As the
-angle increases, the punch force decreases and attributes
a minimum at  = 0
with a 23 mm punch stroke and
reaches an optimum value at  = 15
. The results plotted
from both the experiments and the model show that the
 560
Figure 4.Inuence of the drawing ratio,
, on the BHFs (BHF).
punch forces increase with an increasing punch stroke and
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reach a peak then tend to decrease. Very good correlation
is achieved between the experiments and the predictions for
individual -angles. By analyzing and comparing the gure
for the angles of  = 0
, 5
, 10
, and 15
, it is seen that the
punch force is minimum (55 kN) for  = 0
and the punch
stroke is maximum (36.5 mm) for  = 15
, and it goes to
maximum (83 kN) for  = 5
. Overall, the minimum punch
force is reached at  = 0
and 23 mm of punch stroke,
but the maximum force is reached at  = 5
with 35 mm
of punch stroke. However, the punch stroke is 65 kN for
 = 15
at the same stroke (35 mm). Figure 7 also shows
that the punch stroke decreased with a decreasing -angle
and with increasing friction.
In the model, the BHFs also change with the punch force
and -angle and the effect of the BHF on cylindrical cup
drawing, punch forces at various friction factors for  = 15

is shown in comparison with experimental values in Fig. 8.
The measured and predicted values of BHFs indicate that the
BHF decreases with the increase in punch forces. After the
blank coming into contact with the punch and die shoulders,
the punch load reaches its peak, and then the load decreases
gradually with the ange volume reduction. When the BHF
is too low by depending upon the -angles, a serious tearing
Figure 5.Inuence of friction and the blank holder -angle on the drawing
ratio (
).
S. SEZEK ET AL.
Figure 6.Variation of punch force with stroke for different -angles.
may take place even at low frictions. From the gure
under the same deforming conditions, the BHF decreases
considerably with the decrease of the friction coefcient.
The measured minimum BHF is about 3 kN at m = 06,
which is close to the value determined by the analysis of
FEM. In the deduction of the BHF, the equivalent radius
of the blank corner is supposed to be at the curve edges,
but the dimension of the blank is not reckoned at the long
and short edges. Because of the blank prole relating to the
drawing depth, the BHFs differ a little with the variation in
drawn depth and punch force.
The major forces acting on the blank are axial, friction,
and BHFs, and their distributions plotted for different -
angles are given in Fig. 9. The axial forces (F) increase
slightly by increasing the -angle; however, the BHF and
friction forces (F  ) decrease substantially, especially in
between  = 0
, and then remain stable. This means that
the blank ows into the die cavity more easily, and so the
formability of the blank increases. The BHF, friction, and
axial forces vary between  = 0 and  = 5
. As  = 0
,
Figure 7.Punch force with friction and -angles.
 EFFECT OF DIE RADIUS
Figure 8.Relation between punch force and BHF.
F = 0, F  = 6050 N, and the BHF reaches the value of
10,300 N. However, at  = 5
, F = 250 N, F  = 2000 N,
and BHF takes a value of 4000 N, and after the value of
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 = 5
, the trend is the same and these forces do not
show signicant changes with the -angle. The relation of
critical thickness and BHF is shown in Fig. 10. The cup
wall thinning occurs at the bottom of the cup, and the
thickness deviation is calculated and predicted with respect
to the friction and -angles. The change in blank thickness
for various
, friction, and -angles along the cup wall is
shown in Fig. 11. The BHF increases with a slight increase
in critical thickness and decreases with decreasing friction.
The results show the slight changes in blank thickness along
the deep drawn cup wall zones 16. The variation in blank
thickness with the -angle and the required BHF was shown
in a comparison between the predictions and experiments.
The maximum thinning occurred at zones (3) and (4), and
so the risk of tearing is also going to appear near to these
zones. As seen in the gure, the thinning is the highest
in zones (3) and (4) due to the unfavorable combination
of deformation and other process parameters, such as ,

, m, and BHF. The wall thickness along the cup height
varies greatly depending upon the value of the -angle, in
zone (3). As a result, the maximum thinning was observed
to be less than 6% by depending upon the -angle value.
Figure 9.Force changes with friction and -angles.
561
Figure 10.Changes in blank thickness with
and -angles along the cup
wall.
Figure 12 shows the changes in punch forces with %
deformation. As can be seen, the punch forces increase
sharply up to about 10% deformation and give peaks, and
then decrease with an increasing % of deformation level and
friction for the constant  and
values. Figure 13 shows
the relation between the deep drawing depth, -angle, and
friction (m). The drawing depth increased with an increasing
-angle and increased with decreasing friction. This means
that the deeper cups can be achieved without failure at
higher -angles and at lower frictions. The achieved cup
depth increases up to  = 5
and remains constant for
other  values, but the depth increases considerably with
decreasing friction. The blank wall thickness was called
critical thickness where the maximum deformation and the
deep drawing was achieved without tearing. The critical
thickness variation for a constant value of
= 2175 with
friction and -angle in zone 3 is shown in Fig. 14. As can
be observed from the plotted results, the blank thickness
decreases a little with increasing friction; however, it
increases in high values with decreasing -angles.
The distribution of stresses during the metal ow in the
drawing die cavity is important to know as well as showing
drawability or tearing. In Figs. 15(a)(c) and 16(a)(c), the
Figure 11.Relation of critical thickness and BHF.
 562
Figure 12.Variation of punch forces with percentage deformation and
friction.
stress distributions for different blank holder radii ( = 5

and 15
) are shown for friction factors of m = 02 and
m = 05, respectively. As shown in Fig. 15, the highest
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stresses appeared to be in tensile type at the bottom, and
on the edges of the cup at  = 5
, m = 02 for 50%
of deformation (a); however, the stresses are reduced with
increasing deformation to 70% (b), but increased with
increasing friction (m = 05). The stresses are reduced
at 70% deformation, because after a certain deformation
rate the workpiece is drawn without any failure. However,
due to excesive deformation, such as 70% deformation,
the workpiece becomes very thin and even torn; therefore,
smaller forces needed to carry on the deformation.
Through the analysis, it was seen that the plastic region
was entered at about 10% of deformation, and the stress
concentration was focused on the contact surfaces of the
drawn blank and dies. The blank material was drawn until
the tearing occurs as shown in Fig. 15(b). It was found
that the maximum radial stress along the punch opening
is always located at the bottom of the cup corners. The
location with the predicted radial stress during the drawing
was always found to occur at the upper tangential point
of the punch shoulder where the sheet material disengaged
Figure 13.Relation between the deep drawing depth with -angle and
friction.
S. SEZEK ET AL.
Figure 14.Critical thickness variations with -angle and friction in zone 3.
from the punch. It was, therefore, justied as the most split-
critical location of deep drawing of a cylindrical cup be
about at the radius of the punch corner or at the bottom of
the cup corners. In terms of cup failures, the comparison of
the theoretical model with the experimental results showed
a good agreement, and for the straight cup and bottom side,
both the experiment and the FE simulation also showed
similar results.
The stresses are low and increase considerably with
increasing friction, especially at the contact surfaces. The
cup wall thinning occurred noticeably at zones (3) and
(4) of the bottom intersections of the drawn cup. The
thinning tendency increases with increasing friction, and so
the forming loads also tend to increase. As friction and the
thinning increase, the level of maximum deformation then
lowers to 30%. The fracture and tearing generated after that
level of deformation and the deep drawing process fails. The
rate of formability increased up to 50% for m = 02 and
0.5 and lowered to 30% at higher friction factors. Surely,
the deformation is not only dependent upon the friction but
also the angles of the dies are highly effective parameters.
From the gures, it is observed that the deformation rates
are closer to each other for both  = 5
and  = 15
;
however, it can be seen that slightly higher deformations
can be obtained for  = 15
[Fig. 16(a)]. For example, 60%
of the deformation can be achieved for  = 5
, but 7080%
is achieved for  = 15
. On the other hand, it was also
observed that, as higher deformation rates are achieved for
 = 5
, then the thinning on the cup wall is higher than
that occurring for  = 15
and this is another indication
of the great inuence of die angles on the process. It was
shown that the full deformation is only possible in theory,
for instance for m = 0, and at higher values of friction, the
tearing occurs and this therefore determines the limits of
the process. As tearing occurs at 70% deformation, for the
conditions of  = 5
and m = 02, a similar tearing failure
occurred at 89% deformation for  = 15
[Fig. 16(b)].
Conclusions
A model and experimental analyses were performed to
validate the manufactured deep drawing dies by setting
different -angles and friction. The study provided an
 EFFECT OF DIE RADIUS 563
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Figure 15.Stress distribution in workpiece for  = 5
and (a) 50%, m = 02, (b) 70%, m = 02, and (c) 50%, m = 05.

insight into the deep drawing of DIN 10130-99 steel
blank sheet. The value of
was increased from 1.75
to 2.175 with respect to the -angle without any failure
by using the current die set. The BHFs decreased by
depending upon different values of the -angle and the
advantages of the current design have been validated by
experiments. Furthermore, it is shown that a low BHF
and friction improved the deep drawability of the sheet
material. Through the experiments and the FEM analysis,
it was demonstrated that the punch stroke increased with
increasing die angles, and the optimum results were found
for
= 2175 and  = 15
. It can be concluded from

Figure 16.Stress distribution in workpiece for  = 15
and (a) 50%, m = 02, (b) 89%, m = 02, and (c) 50%, m = 05.
 564
the results that the stress increases with higher values
of friction. The maximum stresses are in tensile and the
minimums are in compressive form. It is evident that the
die radii have the greatest inuence on deep drawing of
the blank sheet followed by the BHF, the drawing ratio
and the friction coefcient. Combining the model results
with the experiments, it can be emphasized that the current
design and analysis can help the optimization of the control
scheme for such deep drawing processes rather than using
conventional die designs and therefore they can be used in
deep drawing more adequately. This type of cylindrical cup
geometry may also be helpful to eliminate noise factors.
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