Study of Strain Pattern in Deep Drawn Square Aluminum Cup

Abstract

This report is aimed to study the different strain pattern in the deep drawn square Aluminum cup. In the automotive industry, significant efforts are being put forth to replace steel sheet with Aluminum alloy. Study of square cup deep drawing can help to study the strain pattern in the complicated geometry shape also. There are different material and processing parameters on which the result of the deep drawing process depends. The performance measure of the deep drawing process is flow limit diagram which shows the major and minor strains.

It this project effect of different materials and processing parameters affecting deep drawing have been studied. Binder force is required for the deep drawing without failure of the component. That is determined by Roff value technique. It takes care of all the parameters affecting deep drawing.

FEA simulations for deep drawing of square cup (50x25x25) are carried out with material as pure aluminum (1100). The simulations are carried out with three different shaped blanks. Minimum strain has been noticed with square blank with corner radius. With same methodology simulations for the aluminum alloy (5052) have been carried out with two different die radiuses. Flow limit diagrams of the above simulations were carried out to study the strain pattern. Macro has been developed in ANSYS parametric design language (APDL) to carry out the above simulations. It reduces the time required for the simulation.

Experimental validation for the deep drawn cup of pure aluminum (1100) has been carried out. Die set is designed for the experiment. Circular grid pattern is marked on the blank to study the strain pattern of deep drawn cup. Laser marking method is used for grid marking. Measurements of the minor and major strains have been carried out on the profile projector. Flow limit curves from the experimental results have been drawn. Simulated results and experimental results are in very good agreement.