Optimization of the Critical Input Parameters for Thickness Distribution in Deep Drawing of Cup for CRCA M.S using Taguchi Method

Deep drawing is a type of sheet metal forming process in which sheet material is plastically deformed by applying deforming force greater than yield and less than ultimate stress. Deep drawing process had wide application in aerospace industry, automobile industry, household utensils, tin cans etc. Most suitable for the mass production purpose. The effect of equipment and tooling parameter resulting into the complex deformation mechanism. It is very important to study the influence of critical input parameters such as Punch nose radius (Rp), Die Shoulder radius (Rd), Blank holder Force (BHF) on the most important output quality characteristics thickness distribution for the sheet of 0.75mm thickness of material CRCA Mild Steel (M.S). Uniform thickness distribution is measured in terms of the minimum variance in thickness from the mean thickness and preferred along the section of cup as it minimizes the stress concentration in part which is main cause for the thinning problem which leads the difficulties in joining and assembling of sheet metal parts. Objective of the research work is to find out the optimum levels of the critical input parameters for the uniform thickness distribution by TAGUCHI signal to noise (SN) ratio method and the optimum levels are Punch nose radius of 7mm, Die shoulder radius of 9mm and Blank holder force of 18.5kN and from the response table of SN ratio Die shoulder radius is most influencing parameter followed by Punch nose radius and last is the Blank holder force.