FINITE ELEMENT ANALYSIS OF BLANK DESIGN OPTIMAL TO PRODUCE A TRIANGLE CUP BY DEEP DRAWING PROCESS

Abstract

The production process of a triangle cup is very difficult method, due to the occurrence violent deformations at a narrow places of the forming region, as a result of non-uniform distribution of hoop compressive stresses and radial tensile stresses, so expected a lot of problems which accompany the forming. The most important is the surplus metal that composed at cup corners, because of the non-homogeneous flow of metals during entry into the die, so appear ears at the upper edge of the cup. To reduce that defect as little as possible, simulation model has been built by program (ANSYS 15) of deep drawing, and modify the blank from circular shape to triangular shape with a gradient corner radii (20, 28, and 35)mm. It was placed at opposite place to the draw tool form.
The effect of the blank form on the required drawn force, distribution of thickness and strains that associated with the forming process were also studied. To make comparison between the experimental results and the results of simulation, it was manufacturing drawing tool with the same specifications of the simulation model. The practical and simulation results showed that the low radii corners of triangular blank lead to failure of deep drawing, especially at radii corners (20 and 28)mm. While the best shape of the cup by used blank with corner radius 35mm, that required less force of drawing, and better distribution of the metal thickness and the strains.