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Materials Today: Proceedings 4 (2017) 2511–2515 www.materialstoday.com/proceedings

5th International Conference of Materials Processing and Characterization (ICMPC 2016)

Analysis of Die Angle in Deep Drawing Process Using FEM

Ajay Kumar Choubeya, Geeta Agnihotrib, C. Sasikumarc, Monika Singhd
a
Research Scholar, Maulana Azad National Institute of Technology, Bhopal, 462003, India
b
Professor, Maulana Azad National Institute of Technology, Bhopal, 462003, India
c
Assistant Professor, Maulana Azad National Institute of Technology, Bhopal, 462003, India
a
B.Tech. Scholar, Department of MSME, MANIT, Bhopal-462003,India

Abstract

In the deep drawing process, maximization of efficiency and minimization of errors is the very important parameters. Deep
drawing technique is averycomplex, costly and widely used manufacturing process, in many industrial applications. In this work,
ANSYS simulation software used for gain accurate and critical understanding of deep drawing parameters. The results were
showing that, the compressive stresses are minimum at 22° die angle at 3.5 mm/sec optimized punch speed.

©2017 Published by Elsevier Ltd.

Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials
Processing and Characterization (ICMPC 2016).

Keywords:ANSYS, Deep Drawing, FEM, Stainless Steel.

* Corresponding author. Tel.: +91-7588190603;

E-mail address: ammitajay.choubey24@gmail.com

2214-7853©2017 Published by Elsevier Ltd.

Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials Processing and
Characterization (ICMPC 2016).
2512 Ajay Kumar Choubey et al. / Materials Today: Proceedings 4 (2017) 2511–2515

1. Introduction

In industrial field, deep drawing process is a very useful because of its efficiency. In deep drawing a blank is drawn
over a die by a punch. The blank is drawn radially inwards the flange undergoes radial tension and circumferential
compression. A blank-holder applies sufficient pressure on the blank to prevent wrinkling on the flange. Punch
speed is most important process parameters in deep drawing technique. Punch speed is the velocity at which the
punch penetrates the work piece. The punch speed should be reduced when cracking or excessive thinning occurs. In
general the speed of drawing should be more in ductile and less for harder materials. Alin Pop et al. has work on
punch speed in deep drawing process. For this study finite element software used and comparing kinetic energy at
various punch speed. [1] Laxmiputra M Nimbalkar et al. has found the optimized punch pressure at different die
angle. For this work 116 no. of substeps used as punch pressure. [2] Idea of conical die was developed from Fukui’s
conical cup test. Abdullah A. Dhaiban et al. has introduced a new technique for production of elliptical shape cup by
conical dies, blank-holder easily eliminate with the help of conical dies of optimized half cone angle. M.A. Hassan
et al. used conical die for developed asymmetric cups with a clover, rose, star and triangular cross sections with
higher drawability. [3-4]

The aim of this numerical investigation is to design a deep drawing geometry without a blank holder by giving an
angle to die. So, for this purpose simulation has done for different die angle.

2. F. E. Model Description

In this analysis, geometry, material properties and applied load is needed. A fine mesh of elements type (SOLID180)
is generated on blank geometry (66 mm of diameter and 2 mm of thickness). The punch and die are assumed to be
solid bodies. The clearance between the punch and die is equal to the initial thickness of blank. The material
properties of the sheet are in Table1.
Table1. Material Properties of Blank [5]
Ultimate Tensile Strength (in
Blank Material Poisson’s ratio Young’s Modulus (in MPa)
MPa)
SS 304/ 821 0.3 200

Figure 1 is showing a finite element model for present deep drawing investigation. By the help of this geometry
blower impellers conical parts will be produced without the use of blank-holder.

Fig. 1 Finite Element Deep Drawing Model

 Ajay Kumar Choubey et al. / Materials Today: Proceedings 4 (2017) 2511–2515 2513

3. Process Parameters & Geometrical Parameters

Different process Parameters are shown in Table 2

Table 2. Process and Geometrical Parameters

Process Parameters
Parameters Value
Punch Speed 3.5 mm/sec
Co-efficient of friction 0.01
Punch Pressure 20 MPa
Geometrical Parameters
Parameters Value
Blank-thickness 2 mm
Die Angle 22°
Punch Fillet Radius 5 mm

4. Results & Discussion

4.1 Testing of Blanks: Cupping Test

Cupping test is a ductility test, and it is used for grading, selecting and sorting of incoming composite materials for
manufacturing of various sheet materials application. [6-7]

20

AA1100
18
SS 304

16
Cupping Test Grade

14

12

10

4
0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2

Thickness (in mm)

Fig. 2. Cupping Test Results and Sample
Figure 2 is showing that the Erichson Cupping Test results of present study. In present study, Stainless Steel (SS
302) and Aluminium Alloys (AA1100) materials are used for cupping test. From 0.5 mm to 2.0 mm thickness
blanks used for formability check. Results were showed that the Stainless Steel formability better as compared to
Aluminium Alloy.
2514 Ajay Kumar Choubey et al. / Materials Today: Proceedings 4 (2017) 2511–2515

4.2 Punch Speed:

Figure 3 is showing that, punch pressure with punch displacement at different speed. It is clearly shown that when
the punch speed is 4.5 mm/sec than the failure occurs at the end of stroke. But no wrinkling occurs at the speed of
3.5 mm/sec.

20

18 3.5 mm/sec punch speed

4.5 mm/sec punch speed
16
Punch Pressure (in MPa)

14

12

10

0 10 20 30 40 50

Punch Displacement (in mm)

Fig. 3. Punch Pressure vs Punch Displacement
4.3 Die Angle:
From the finite element simulation, the thinning region and probable failure regions can be identified. Maximum
stress regions are the major regions of failures.Finite element simulation helps in avoiding prototype built up and
checking for the required load calculations. 220 die inclinations are giving the minimum stresses in the sheet metal.
The coefficient of friction is 0.001 for tool set. Figure 4 is showing variation compressive stress over die angle.

15.5

15.0
Compressive Stress (in MPa)

14.5

14.0

13.5

13.0

12.5
18 20 22 24 26 28 30

Angle of Die (in degrees)

Fig. 4. Variation of Compressive Stress on Various Angle of Die
 Ajay Kumar Choubey et al. / Materials Today: Proceedings 4 (2017) 2511–2515 2515

4.4 Numerical Cup:

Figure 5 is showing that a successful quarter model of stainless steel numerical cup at 22 degree dies angle with 5
mm punch fillet radius on 3.5 mm/sec. punch speed.

Fig. 5. A proper colour band for simulation cup at 22° die angle

Conclusion

It is very clear that finite element analysis is the best method to use for study of deep drawing process.Erichson
cupping test findings were showed that the Stainless Steel formability better as compared to Aluminium Alloy.
Simulations conducted show that only at speeds below 3.5 mm/s,stressesareminimum.The results were show that the
stresses are minimum on 5mm punch fillet radius, with 3.5 mm/sec punch speed. Also the simulation results state
that the optimized punch pressure for stainless steel cup is 16 MPa on 35 mm punch stroke.

References:
[1] Alin Pop, IoanRadu, Florin Blaga, “Finite Element Analysis Study on Deep Drawing Speed Punch”, Nonconventional Technologies
Review (2015) 46-50.

[2] Laxmiputra M Nimbalkar, Sunil Mangshetty, “Analysing the Effect of Blank Holder Shape in Deep DrawingProcess Using Fem”,
International Journal of Engineering Research and Development, 4 (2012) 23-28.

[3] Abdullah A. Dhaiban, M.-Emad S. Soliman, M.G. El-Sebaie, “Finite element modeling and experimental results of brass elliptic cups using
a new deep drawing process through conical dies”, Journal of Materials Processing Technology 214 (2014) 828–838.

[4] M.A. Hassan, I. M. Hassab-Allah, L. M. A. Hezam, N. A. Mardi, M. Hamdi, “Deep Drawing of Asymmetric Cups through Conical Die
without Blank Holder”, Proceedings of the World Congress on Engineering, II (2015).

[5] K Mohan Krishna, M Kumara Swamy, “Prediction of Draw Ratio in Deep Drawing through Software
Simulations”, International Refereed Journal of Engineering and Science, 3 (2014) 24-29.

[6] AnimeshTalapatra, Sujit Kumar Agarwal, SanjibPandit, AyanSengupta, JoydeepSaha, “Formability Characterization of Composite Sheet
Materials by Erichsen Cupping Testing Method”, International Journal of ChemTech Research, 6 (2014) 2014.

[7] R.Uday Kumar, G. Chandramohan Reddy, “Evaluation of Ericson Number and Peak Load of Sheet Metals”, International Journal of
Advanced Materials Manufacturing & Characterization, 3 (2013) 381-384.