FEA Simulation of Warm Deep Drawing Process

Abstract

Sheet metal forming is one of the most basic and versatile process which is having highest applicability in Modern world applications , Considering wide applicability of deep drawing process in sheet metal forming product industries, this basic process has been selected for study. Formability of sheet metal is a ected by various material and process parameters, where temperature at which process is carried out plays a major role in determining the success rate and time required for manufacturing product of sheet metal. SS 304 grade austenitic steel changes its state to martensite grade due to strain hardening during cold working process which requires annealing at de nite values of strain produced in order to increase its formability,In order to eliminate this need of annealing,temperature can be combined with process by means of induction heating and control.This requires grate amount of trial and error work, Thus help of FEA SIMULATION is taken in order to predict the e ect of temperature on the process variables and number of stages required to draw the component successfully thus minimizing experimental trial and error which will save time and cost of experiments. In this study uniaxial tensile test has been performed with di erent specimen from all rolling direction (0,45,90 degree) at room temperature and elevated temperature in order to obtain mechanical properties of SS 304 stainless steelwhich are used as input for simulation and results are compared.In order to check e ect of temperature on number of redraw required, a typical component which requires process of four stages at room temperature is chosen and attempt is made to reduce number of stages required in the process.The results show with optimum process parameters the rst two stages of the four stage manufacturing process can be combined at room temperature condition,Therefore number of stages required to draw the component reduces to three stages and using elevated temperature properties rst three stages of four stage manufacturing process can be combined, Therefore reducing the number of stages required to draw the component to two using optimum parameters. This study will help to reduce, the time required for production of typical component by reducing number of redraws required, cost of extensive experiments, and will improve productivity. Here help of FEA simulation is taken to analyze the possibility of reduction of num- ber of stages required from four to three at room temperature condition, and it is also shown that the process can be modi ed further from three stages to two stages using warm deep drawing process, which will be helpful to save the time and cost of experiment.