Study the Effect of Blank Holding Force on Deep Drawing of Aluminum Alloy Square Cup

Abstract

Today the automobile industries are constantly being asked to meet demand for quality product standards, demand of lighter, safer and cheap vehicle. To achieve such property Aluminum alloy is the best substitute. Now in these days maximum part of automobile is replaced by the aluminum alloys and the use of steel is reduced. The main problem occurs in the use of aluminum, and tailor blanks are in their forming process. It is required to maintain their forming quality.

This project is aimed to study the effect of different Blank Holding Force on deep drawing and to study the various process parameters that affect the control of blank holding force. This includes the finite element simulation of deep drawing process of square cup and experimental validation for the same by using the segmented blank holder.

The affect of variable blank holding force on ‘Tailar welded blank’ have been discussed in this report. Die and punch for drawing (50*50*25 mm size) was designed and manufactured for experimental validation. Strain is measured by measuring deformation of circular grids. Circular grids have been marked with help of laser marking machine. Finite element simulation is carried out for a square cup and the affect of blank holding force have been studied. A macro is developed to carry out several iterations. This reduced the modeling time to a great extent. Material used is 5052 aluminum alloy and 1100 aluminum. Finite element simulation is in very good agreement with the experimental results.