International Journal of Research and Innovation (IJRI)

International Journal of Research and Innovation (IJRI)

1401-1402

SIMULATION OF DEEP DRAWING DIE FOR OPTIMIZED

DIE RADIUS USING FEM TECHNIQUE

G.Bhargav*, K.Durga
1.Research Scholar, Department of Mechanical Engineering,Vikas college of Engineering and Technology,Nunna, Vijayawada rural,
Krishna (DIST),Andhrapradesh,India.
2.Assistant Professor, Department of Mechanical Engineering, Vikas college of Engineering and Technology,Nunna, Vijayawada rural,
Krishna (DIST),Andhrapradesh,India.

Abstract
Deep drawing process is one of the most used Metal Forming Process within the industrial field. Different analytical,
numerical, empirical and experimental methods have been developed in order to analyze it. This work reports on the
initial stages of finite element analysis (FEA) of a Deep drawing process.
The objective of this study is to determine theinfluencingof die radius in drawing process and analyzing the process by
varying the Die radius and keeping the Friction, and Blank Thickness as constant.
In this paper Punch and blank thicknessissame;die with various geometries (with various corner radius) were drawn by
using PRO/Engineer software. And an effort is made to study the simulation effect of main process variant namely die
radius using finite element analysis.
Initially literature survey will be done to describe about deep drawing process and effect of die radius in press tools.
FEA models will be generated using PRO/Engineer.
Structuralanalysis will be carried out to determine the structural characteristics with the change of corner radius.
Structural analysis will be carried to find the actual effect of radius in process and also to find limiting radius value
for the same.
Transient analysis will be carried to find the actual effect of radius in process and also to find limiting radius value for
the same with the variation of time period.
*Corresponding Author:
G.Bhargav ,
Research Scholar, Department of Mechanical Engineering,Vikas
college of Engineering and Technology,Nunna, Vijayawada rural, Krishna (DIST),Andhrapradesh,India.
Published: December 16, 2014
Review Type: peer reviewed
Volume: I, Issue : IV

Citation: G.Bhargav Research Scholar, (2014) SIMULATION OF DEEP DRAWING DIE FOR OPTIMIZED DIE RADIUS USING FEM TECHNIQUE

Introduction To Sheet Metal

Method of Analysis
In general, the complexity of these processes and
the great number of factors involved in them making very difficult to select the parameter values
properly.
Then, different analytical, numerical and experimental methods are being developed in order to
analyze the best combination of them. Now-a-days
analytical methods still continue being studied and
developed in spite of numerical methods allow ob-

taining solutions with high precision and detail evels in the analysis of this type of process.
Finite element method has been used as well in several studies about metal forming processes recently.
The main objective of this paper presented in it is
the multi stage deep drawing analysis. According to
John Monaghon et al, as the die radius is reduced,
this increases the amount of force required to draw
the material. The increased force on the punch and
the greater difficulty in getting the material around
the die radius causes stretching marks on the cup
wall and an uneven thickness distribution. To verify the above experimental results and to validate
the simulation done, several simulations were performed by varying the die radius. Furthermore, the
effect of the above process parameters on the formability and quality issues are studied.
The stamping of thin metallic sheets is a widely
used industrial material forming process. It allows
production of thin walled parts with complicated
shapes such as automotive panels or structural
parts. The process consists of the plastic deformation of an initial at blank subjected to the action
of a rigid punch and die while constrained on the
periphery by a blank holder.

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International Journal of Research and Innovation (IJRI)

The main variables involved in this type of process

are:
Die Radius
Friction
Punch Radius
Blank Thickness.
These factors determine the maximum punch load
in drawing, the sheet-thickness variation after
drawing, and the maximum limit drawing ratio. If
the height ofthe work piece in industrial production
is too high, multi-redrawing is necessary in order to
obtain a successful product.
The finite element method has recently been sufficiently developed for the analysis of metal forming processes. Hence, much research has been
performed using the finite element method. The
purpose of this study is to clarify the mechanics of
ductile fracture in bulk metal forming processes.
The following four kinds of ductile fracture criteria, that is to say, freudenthals fracture criterion,
Cockcroft and lathams fracture criterion, Brozzo
et al.s fracture criterion and oyanes fracture criterion are used. These four kinds of ductile fracture
criteria are used in the analysis of deep drawing.
The analytical results of the work using Cockcroft
and lathams fracture criterion and using Brozzo et
al.s fracture criterion agree satisfactorily with the
experimental result.
Sheet metal
Sheet metal is metal formed by an industrial process into thin, flat pieces. It is one of the fundamental forms used in metalworking and it can be
cut and bent into a variety of shapes. Countless
everyday objects are constructed with sheet metal.
Thicknesses can vary significantly; extremely thin
thicknesses are considered foil or leaf, and pieces
thicker than 6 mm (0.25 in) are considered plate.
Sheet metal is available in flat pieces or coiled strips.
The coils are formed by running a continuous sheet
of metal through a roll slitter.
The thickness of sheet metal is commonly specified
by a traditional, non-linear measure known as its
gauge. The larger the gauge number, the thinner
the metal. Commonly used steel sheet metal ranges
from 30 gauge to about 8 gauge. Gauge differs between ferrous (iron based) metals and nonferrous
metals such as aluminum or copper; copper thickness, for example are measured in ounces (and represent the thickness of 1 ounce of copper rolled out
to an area of 1 square foot).
There are many different metals that can be made
into sheet metal, such as aluminum, brass, copper, steel, tin, nickel and titanium. For decorative
uses, important sheet metals include silver, gold,
and platinum (platinum sheet metal is also utilized
as a catalyst.)
Sheet metal is used for car bodies, airplane wings,
medical tables, roofs for buildings (architecture)
and many other applications. Sheet metal of iron

and other materials with high magnetic permeability, also known as laminated steel cores, has applications in transformers and electric machines.
Historically, an important use of sheet metal was in
plate armor worn by cavalry, and sheet metal continues to have many decorative uses, including in
horse. Sheet metal workers are also known as "tin
bashers" (or "tin knockers"), a name derived from
the hammering of panel seams when installing tin
roofs.
Material used for sheet metal process
Stainless steel
Usage of steel as a building material is popular as
a cost effective, quality material as compared to the
alternatives. The three most common stainless steel
grades available in sheet metal are 304, 316, and
410.
Grade 304 is the most common of the three grades.
It offers good corrosion resistance while maintaining formability and weldability. Available finishes
are #2B, #3, and #4. Grade 303 is not available in
sheet form
Grade 316 possesses more corrosion resistance and
strength at elevated temperatures than 304. It is
commonly used for pumps, valves, chemical equipment, and marine applications. Available finishes
are #2B, #3, and #4
Grade 410 is a heat treatable stainless steel, but
it has a lower corrosion resistance than the other
grades. It is commonly used in cutlery. The only
available finish is dull.
Aluminium
Aluminium is also a popular metal used in sheet
metal due to its flexibility, wide range of options,
cost effectiveness, and other properties.[4] The four
most common aluminium grades available as sheet
metal are 1100-H14, 3003-H14, 5052-H32, and
6061-T6.
Grade 1100-H14 is commercially pure aluminium,
highly chemical and weather resistant. It is ductile
enough for deep drawing and weldable, but has low
strength. It is commonly used in chemical processing equipment, light reflectors, and jewelry.
Grade 3003-H14 is stronger than 1100, while maintaining the same formability and low cost. It is corrosion resistant and weldable. It is often used in
stampings, spun and drawn parts, boxes, cabinets,
tanks, and fan blades
Grade 5052-H32 is much stronger than 3003 while
still maintaining good formability. It maintains high
corrosion resistance and weldability. Common applications include electronic chassis, tanks, and
pressure vessels
Grade 6061-T6 is a common heat-treated structural
aluminium alloy. It is weldable, corrosion resistant,
and stronger than 5052, but not as formable. It los61

International Journal of Research and Innovation (IJRI)

es some of its strength when welded.[3] It is used in

modern aircraft structures.
Part Modeling In Pro/Engineer

Guide pillars are used to guide the core to assemble

in desired location in process.
The above image is showing final part of cavity

The above image is showing final part of core

A) Top booster is placed on cavity plate to prevent

direct interaction with power press hammer
B)Counter head and hole is used to assemble the
top booster to the core.

Above Figure
A) Cavity hole which creates outer impression of component.
B) Chamfer is used to reduce the errors of guide pillar relocation.
C) Guide holes are used to place the guide pillar in running process.
D)Guide slots are used to place the clamps for fixing.

Above Figure

A) Corner radius is preferred for punching and drawing to prevent damage to the sheet it effects operation speed and quality.
B)Core (or) male part is used to make inner impression on object
and dia is depends on the same.
C)Core supporting plate is connected with top booster it includes
core part.

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International Journal of Research and Innovation (IJRI)

Draw tool calculations

Analysis of cup drawing:

Input:
punch height
Punch diameter
Thickness
Cup diameter

=
=
=
=

100mm
20mm
1mm
22mm

Calculations of blank diameter:

Cup to be drawn
Diameter = 91.65
Height = 100mm

DO =(dn2+ 4 dn hn)
= (91.652+491.65100)
= 212.27mm
Calculations of drawing ratio:
4 stages of deep drawing is preferred for 100 (or)
below heights
1st draw
-3.818 to 3
2nddraw
- 3 to 2
3rddraw
- 2 to 1
4thdraw
-1 to 0
Results

1.In case of cup the blank is circular

2.Area of blank is
(D0)/4 = (d0)/4 + d1h

No .of operations

Height in mm

Diameter in
mm

Drawing ratio

0 blank

____ _____

91.65

____ _____

1st draw

25

74.7365

0.95

2nddraw

50

57.824

1.9

3rddraw

75

40.91

2.86

4thdraw

100

24

3.818

Do =(d12+ 4d1h)

Equivalent strain

Do = (202+ 420100) = 91.65mm

Strain in the direction of 3 axis

= 2=91.65 ;2 = w = 91.65 ; 3= th = 1

Blank piece diameter = 91.65mm

Limiting Drawing Ratio(LDR):
B = (Do/dn)

Equivalent strain:

Bi= (d)/(d+1)
B = 91.65/22= 4.615

e = 2 / 3((1-2)+(2-3)+(1-3))
= 2 / 3 ((91.65-91.65)+(91.65-1)+(91.65-1))
=2 / 3 ((0)+(90.65)+(90.65))
= 0.47 (8217.4+8217.4)
= 0.47 16434.8
= 60.253

First drawing B1= 3.9 to 3.0

Introduction To Ansys

Redraw Bi = 3.0 to 1.0 (for copper, aluminum and

mild steel)

ANSYS is general-purpose finite element analysis

(FEA) software package. Finite Element Analysis
is a numerical method of deconstructing a complex
system into very small pieces (of user-designated
size) called elements. The software implements
equations that govern the behaviour of these elements and solves them all; creating a comprehensive explanation of how the system acts as a whole.
These results then can be presented in tabulated,
or graphical forms. This type of analysis is typically
used for the design and optimization of a system far
too complex to analyze by hand. Systems that may
fit into this category are too complex due to their
geometry, scale, or governing equations.

DO = diameter of blank
dn= smallest diameter (cup diameter)
Draw ratio in general:

Draw force:
Fd max = n d t UTS
d = Diameter of cup
t = thickness
UTS = Ultimate Tensile Strength
n = Drawing coefficient (0.7 to 0.95)
Fd max=0.7 3.1422 1162
= 7833.672 MPa

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International Journal of Research and Innovation (IJRI)

Boundary conditions:

Solution

Constrained at thickness direction for cup analysis.

Constrained cavity area for die analysis.
Force= 7833.672 MPa

Solution Solve Current LS ok

Structural Analysis Of Draw Tool With 4 Raidus

(Stainless Steel Sheet)

General Post Processor Plot Results Contour Plot

- Nodal Solution DOF Solution Displacement
Vector Sum

The above image is the imported model of draw tool.

Modeling was done in Pro-E and imported with the
help of IGES (Initial Graphical Exchanging Specification).
Meshed Model

The above image shows the meshed modal. Default

solid Brick element was used to mesh the components. The shown mesh method was called Tetra
Hydra Mesh.
Meshing is used to deconstruct complex problem
into number of small problems based on finite element method

The above image shows the loads applied

Post Processor

The above image shows displacement value 0.00726

mm

The above image shows von-misses stress value

12.365 N/mm2
Structural Analysis Of Draw Tool Die With 4 Raidus (Stainless Steel And Tool Steel)

The above image is the imported model of draw tool

die with 4mm radius. Modeling was done in Pro-E
and imported with the help of IGES (Initial Graphical Exchanging Specification).
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International Journal of Research and Innovation (IJRI)

Meshed Model

The above image showing the meshed modal. Default solid Brick element was used to mesh the components. The shown mesh method was called Tetra
Hydra Mesh.

Transient Analysis Of Draw Tool Die With 4 Radius (Stainless Steel And Tool Steel)

The above image shows displacement value 0.305595 mm

General Post Processor Plot Results Contour Plot Nodal
Solution Stress Von Mises Stress

Meshing is used to deconstruct complex problem

into number of small problems based on finite element method
Post Processor
General Post Processor Plot Results Contour Plot
- Nodal Solution DOF Solution Displacement
Vector Sum
The above image shows von-misses stress value 2114.09 N/mm2

The above image shows displacement value 4.29347

mm
General Post Processor Plot Results Contour Plot
Nodal Solution Stress Von Mises Stress

The above image shows displacement value 0.305595 mm

The above image shows von-misses stress value 7258.09 N/mm2

The above image shows von-misses stress value 2114.09 N/mm2

General Post Processor Plot Results Contour Plot Nodal Solution Stress Von Mises Stress

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International Journal of Research and Innovation (IJRI)

Graphs
For Part

The above image shows strain value 0.025091

The above image shows von-misses stress graph

For die part

Results Table
Cup
4 radius

5 radius

6 radius

7raidus

8 radius

Displacement
In mm

0.00072

0.00095

0.00073

0.00153

0.00190

Stress
In N/
mm2

12.365

16.1762

7.57467

19.7477

34.3424

Draw tool die

4 radius

5 radius

6 radius

7raidus

8 radius

Displacement
In mm

4.29347

8.065

10.7043

19.3959

16.7185

Stress
In N/
mm2

7258.09

7841.36

8515.06

11323.8

9811.01

Draw tool die transient

4 radius

5 radius

6 radius

7raidus

8 radius

Displacement
In mm

.3

.91

1.48

1.34

1.72

Stress
In N/
mm2

2114

3076

3814

4326

3954

Strain

.025

.017

.025

.028

.022

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International Journal of Research and Innovation (IJRI)

For die transient analysis

As per the analytical results this work concludes as

below.
1) Corner radius mainly effects on process speed
and required force.
2) Increment of corner radius up to certain limit improves production rate quality.
3) As per the cup and die analysis results 7 radius
is the better option.
4) 8 radius die performance is comparatively low
than 7 radiuses die.
5) 7 radius die is providing maximum force on sheet
to become sheet into desired cup shape.
References
1) KopanathiGowtham, K.V.N.S. Srikanth & K.L.N.
Murty
2) Yuung-ming HUANG, Shiao-cheng LU
3) R.UDAY KUMAR
4) G. Venkateswarlu, M. J. Davidson and G. R. N.
Tagore
5) Y. N. Dhulugade1, P. N. Gore2
Authour

G.Bhargav*
Research Scholar, Department of Mechanical Engineering,Vikas
college of Engineering and Technology,Nunna, Vijayawada rural,
Krishna (DIST),Andhrapradesh,India.

Conclusion
The objective of this project work is to present effect
of radius in deep drawing process and to suggest
the optimum value of radius, for presenting the required values following process is done using FEM
technique.
Literature survey and data collection is done to
understand the deep drawing process, requirements and effects of radius.
General models and FEA models are prepared for
further study.
Structural analysis is carried out on component
and die structure by varying the corner radius values of 4,5,6,7 and 8
Transient analysis is carried out to determine the
values of punch deformation and stress, also to determine stresses developing on sheet.
Graphs are created for better understanding of results.

K.Durga
Assistant Professor, Department of Mechanical Engineering, Vikas college of Engineering and Technology,Nunna, Vijayawada
rural, Krishna (DIST),Andhrapradesh,India.

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