Modelling and Simulation of Deep Drawing Process of Circular Cup on AL1200 Using Finite Element Analysis

Deep drawing process is the mostly used sheet forming process. This method is used in the automobile and aerospace industries and also used for the production of kitchen utensil and cold drink cans. In deep drawing, there are some factors which influence the process those factors are called process parameter of deep drawing. Blank holding force, friction, strain rate, thickness, blank shape, temperature, punch force and punch speed, etc. are the most important parameters. Wrinkles and spring back defects in the drawn component are highly undesirable defects. Wrinkling when insufficient holding force is applied on flange. The objective of this work is to analyze the wrinkling and spring back problem in the deep drawing of circular cup and to determine range of process parameters to minimize the wrinkling defect and spring back defect. A finite element model is developed for 3-D numerical simulation of a circular cup for blank material AL1200 forming process in finite element software ABAQUS 6.14 and ANSYS18.1/APDL. Properties and tool design parameters were used as input parameters for simulation. Wrinkling and spring back defect was observed in the simulated cup. From the FE simulation, we found out the minimum wrinkling occurs in the deep drawn cup at flange region when the Blank holding force is 1 KN and coefficient of friction is 0.02 and the minimum spring back effect occurs in the deep drawn at the BHF of 1 KN and friction of 0.01. Max punch pressure is needed to draw a component when punch velocity is 0.23 mm/s, friction 0.01 and BHP of 33 MPa. Defects like cracking, tearing and necking are not observed in the deep drawn components.