Sheet metal forming is an important process in most industries where large-sized products are deep drawn for obtaining the complex shape of products at higher productivity rates. During deep drawing process industries often experience failures like wrinkling, fracture, tearing and earring of the sheet metal. Different aspects of these failures are discussed in this paper so as to minimize these failures. The methodology followed is: adopting a standard theoretical design; performing a computational analysis using software package ANSYS and comparing experimental results with our simulations. A particular set of industrial data is used for this analysis which helps to evaluate the causes of failures. It is determined that low pressure leads to wrinkling on/nearby the flange area, while excess pressure causes sudden fracture or tearing through the sides/wall surface. Also optimum pressure is determined experimentally for standard commercial products so as to avoid the failures during the process. The simulation results of ANSYS are in conformance with the experimental data showing the maximum thickness reduction ratio and the maximum depth of draw. Failures can then be predicted with a good accuracy for different designs of products from simulated values.
Journal of Failure Analysis and Prevention – Springer Journals
Published: Jun 4, 2018
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