Investigation and establishment of rational geometric factors of die in the deep drawing without a blank holder

Abstract

Deep drawing is an operation to transform flat or hollow blanks to create hollow parts of the required shape and size. Deep drawing is an essential operation in sheet-forming technology to manufacture hollow parts. These parts are commonly used in the automobile, aviation, and household appliances industries. To prevent wrinkles on the rim part, a blank holder will be used to compress and flatten the workpiece before the metal is pulled into the die by the punch. Deep drawing without using workpiece holding force is applied to form hollow parts with low depth. In this case, the mould has a simple structure, helping to reduce manufacturing time and costs and making it easier to maintain and repair. The radius of the die is an essential parameter in deep drawing; it greatly affects the quality of products (making wrinkles and tears). However, this study has shown that, in deep drawing without using a blank holder, the cone angle of the die α has a major influence on the quality of the body and rim of the products, such as the products may or may not have wrinkles, either being thinned or thickened. This cone angle also affects the drawing force. This study has determined that, with α>120°, wrinkling begins to appear in the part wall, and wrinkling tends to increase as the angle α increases. The cone angle of the die for quality products is in the range of 100°<α≤120°. The taper angle smaller than 120° simultaneously increases the quality of the products and the cost of manufacturing die, so the most optimal value is determined by simulation and experimental verification as α=120°. The results of this study can be applied to fabricate hollow cylindrical parts with similar shapes when using the deep drawing method without using the blank holder