Optimizing the Behavior of Deep Drawing Process with Stress and Strain Variation using Finite Element Simulation by Changing Different Die Angle

Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. Deep drawing process is a shape transforming method. Defects like cracks and wrinkling of deep drawing occur very often in conventional cylindrical deep drawing process because of the lower forming ability of aluminum alloy sheet at room temperature. Therefore, a different approach is discussed in my research to obtain some new prediction of behavior with variations of deep drawing. This method helps to push the sheet metal in different angular direction. In addition, the effect of co-efficient of friction is predicted while performing deep drawing. In order to avoid the costly, tedious and difficult experiments, modern manufacturing industry is based on the analysis of forming processes in numeral atmosphere before the actual production set-up. In the work, the single stage deep drawing process is used by means of a finite element analysis. Simulation of the deep drawing process for determining stress distribution in the drawn component for different variations is explained in my work. The distribution of stress in the drawn component is obtained. Thus simulation of deep drawing is being carried out on alloy steel at different die angles and to check its performance. Also its behavior is tested at various co-efficient of friction. The result of simulation will be beneficial to the tool designer and the manufacturing industries doing work in this field.