Modelling of Sheet Metal Process using Finite Element Analysis 2DCAD Model to Find the Optimum Sheet Thickness

Abstract

Deep drawing is popular sheet metal forming process. Complex axisymmetric geometries, and certain nonaxisymmetric geometries, can be produced in a few operations in small cycle time. Skill requirement of operator is relatively less. The basic theories governing the deep drawing are based on application of theory of plasticity to the deep drawing process. It is very difficult to apply these theories and arrive at a general solution which can handle any arbitrary geometry. Some simpler ‘mechanics models’ are more appropriate for such cases, though these do not incorporate all the aspects governing the process. Therefore, design in sheet metal forming, even after many years of practice, still remains more an art than science due to the large number of parameters involved in deep drawing and their interdependence. Design of tooling for deep drawing (die, blank holder and punch) has been largely based on trial and error resulting in loss of time and money and large development cycles. Using the finite element method one can simulate the process and study the effect of various parameters before finalizing the design. Several simulation tests were carried out to obtain the most appropriate value for some of the parameter. A computational experiment is made to explore the effect of process variables on stress distribution and punch load. An elastic-plastic finite element computational program is developed to simulate successive deep drawing process.