Parametric Finite Element Analysis of square cup deep drawing
Purpose: This paper deals with the FEA of the sheet metal forming process that involves various nonlinearities. Our objective is to develop a parametric study that can leads mainly to predict accurately the final geometry of the sheet blank and the distribution of strains and stresses and also to control various forming defects, such as thinning as well as parameters affecting strongly the final form of the sheet after forming process. Design/methodology/approach: In cold forming (deep drawing) operation, sheet metal is subject to large strains in order to obtain the final desired shape. However, under severe forming conditions the sheet metal may experience some thinning and even some tearing during the process. Parameters of the deep forming process that may contribute to such conditions include, aspect ratio, blank initial thickness, forming temperature, shoulder radii of the die and punch, contact conditions between the blank and the die, holder and punch, punch displacement rate, etc. The work presented in the current paper is a first part study of numerical parametric investigation that is dealing with the most influent parameters in a forming process to simulate the deep drawing of square cup (such as geometric parameters and coefficient of friction) The purpose of the current paper is to conduct a validation study of the FEM model that is used to conduct the study described above. In fact, a 3D parametric FEA model is built using ABAQUS /Explicit standard code. Findings: A methodology to develop this kind of theoretic resolution is pointed out and has been illustrated for a set of variables. Several 2D and 3D plots, which can be used to predict incipient thinning strengths for sheets with flat initial configuration, have been presented for the various loading conditions. Research limitations/implications: As it was mentioned above, this paper is the first part of a study of the numerical parametric investigation that is dealing with the most influent parameters in a forming process to simulate the deep drawing of square cup (such as geometric, material parameters and coefficient of frictions)