A novel approach to the conventional deep drawing process

In this study, the mechanical formability of Al6061-T6 sheet material using a pre-bulging process was experimentally investigated. Therefore, an innovative die entrance design was applied to conventional deep drawing dies. In addition to the formability of the Al6061-T6 material, the effects of the innovative design on the energy consumption and thickness distribution were also investigated. For the experimental studies, deep drawing dies capable of mechanically pre-bulging at 0 degrees, 15 degrees, and 30 degrees angles were designed and experimental studies were carried out at a 10 mm/sec forming speed with constant blank holder force. It was observed that the Al6061-T6 material, which was drawn at the highest ratio of ss = 2.0 in a single operation with the conventional deep drawing method, can be deep drawn at a drawing ratio of ss = 2.2 in a single operation with this new method, and the forming force was reduced by 24.45%. It was found that the deep-drawn Al6061-T6 sample, which was drawn at the highest ss = 2.2 drawing ratio, exhibited a maximum sheet thinning of 15%, and it could be formed with a single die in a single operation without forming defects such as cracking and wrinkling.