Effect of Forming Method on the Behavior of the Drawing Process of a Complex Shape

This paper aims to produce a complex shape with eight vertices in a deep-drawing process. Two methods were used to perform this study. The first method is called the direct method (drawing process), in which a complex shape was produced directly from drawing metal sheets. The second method called the indirect method (redrawing process) involves producing a complex shape from the re-drawing process of the cylindrical shape previously drawn from sheet metal. The two methods were also compared in terms of drawing force, thickness distribution, stress, and strain distribution. The sheet metal used in this work is made of low carbon steel (1008-AISI) with dimensions of 0.7 mm in thickness and 80 mm in diameter. In the present study, ANSYS 18.0 software was used for simulating the drawing and redrawing process. The results indicate the maximum drawing force with a drawing process (41 KN EXP, 30 KN FES). The effective stress and the effective strain increase until the cup’s end and reach the maximum values of the effective stress (835.23 MPa FES) and the effective strain (0. 442 FES, 0.345 EXP) in the area of the minor axis curvature with the process of re-drawing. The maximum thinning at the corner area with the redrawing process (7. 143% FES, 5.722% EXP) at the zone of the minor axis curvature. Also, the best distribution of thickness, stresses, and strains along the wall of the complex shape with the first method (drawing process).