A novel approach to the conventional deep drawing process

Kabakçı M. O., Karaağaç İ., Demirel M. Y.

PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS, PART E: JOURNAL OF PROCESS MECHANICAL ENGINEERING, vol.237, no.2, pp.280-289, 2023 (SCI-Expanded) identifier identifier

  • Publication Type: Article / Article
  • Volume: 237 Issue: 2
  • Publication Date: 2023
  • Doi Number: 10.1177/09544089221103496
  • Journal Name: PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS, PART E: JOURNAL OF PROCESS MECHANICAL ENGINEERING
  • Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Aerospace Database, Applied Science & Technology Source, Communication Abstracts, Compendex, INSPEC, Metadex, Civil Engineering Abstracts
  • Page Numbers: pp.280-289
  • Keywords: Deep drawing, die entrance type, pre-bulging, drawbead, Al6061-T6, ALUMINUM-ALLOYS, RADIAL PRESSURE, ENHANCING FORMABILITY, MAGNETIC MEDIUM, SHEET, PART, OPTIMIZATION, PARAMETERS, BEHAVIOR
  • Gazi University Affiliated: Yes

Abstract

In this study, the mechanical formability of Al6061-T6 sheet material using a pre-bulging process was experimentally investigated. Therefore, an innovative die entrance design was applied to conventional deep drawing dies. In addition to the formability of the Al6061-T6 material, the effects of the innovative design on the energy consumption and thickness distribution were also investigated. For the experimental studies, deep drawing dies capable of mechanically pre-bulging at 0°, 15°, and 30° angles were designed and experimental studies were carried out at a 10 mm/sec forming speed with constant blank holder force. It was observed that the Al6061-T6 material, which was drawn at the highest ratio of ß  =  2.0 in a single operation with the conventional deep drawing method, can be deep drawn at a drawing ratio of ß  =  2.2 in a single operation with this new method, and the forming force was reduced by 24.45%. It was found that the deep-drawn Al6061-T6 sample, which was drawn at the highest ß  =  2.2 drawing ratio, exhibited a maximum sheet thinning of 15%, and it could be formed with a single die in a single operation without forming defects such as cracking and wrinkling.