• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.6
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• pp.1077-1084
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• 2002

Optimum tool design is carried out fur a multi-stage rectangular cup deep-drawing and ironing process with the large aspect ratio. Finite element simulation is carried out to investigate deformation mechanisms with the initial design made by an expert. The analysis considers the deep drawing process with ironing for the thickness control in the cup wall. The analysis reveals that the difference of the drawing ratio within the cross section and the irregular contact condition produce non-uniform metal flow to cause wrinkling and severe extension. For remedy, the modification guideline is proposed in the design of the tool and the process. Analysis results confirm that the modified tool design not only improves the quality of a deep-drawn product but also reduces the possibility of failure. The numerical result shows fair coincidence with the experimental one. After tryouts of the tool shape, the rectangular cup has been produced in the transfer press.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.85-88
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• 2001

Examination of the die design is carried out for a multi-stage rectangular cup drawing process with the large aspect ratio with the aid of the finite element analysis. The analysis considers the deep drawing process with the ironing process for the thickness control in the cup wall. Simulation is performed to investigate the deformation mechanism in the initial design and the modified design. The analysis clarifies that the irregular cross section and the irregular contact condition produces unfavorable deformation. The analysis results show that the modified design improves the quality of a deep-drawn product with the low possibility of failure. The analysis result also shows good agreement with the experimental one.

• Transactions of Materials Processing
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• v.24 no.2
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• pp.115-120
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• 2015

Deep drawing of cylindrical cups is one of the most fundamental and important processes in sheet metal forming. Circular cups are widely used in industrial fields such as automobile and electronic appliances. Some of these cups are formed by a one-stage process, others such as battery cases and beverage cans are made by a multi-stage process. In the current study the multi-stage deep drawing of aluminum sheet metal is examined. The process consists of two deep drawing operations followed by two ironing operations. The press die, which can be used for the four-stage forming process, was manufactured allowing punch and die components to be easily changed for various experiments. The rolling direction of both the sheet and the drawn cups was always positioned toward the horizontal x-direction on the die face to minimize experimental errors during the progressive forming. The dimensional accuracy of the cylindrical cups formed at each stage and the earing defect due to the anisotropy of sheet were investigated. The influence of anisotropy on the thickness distribution was also examined. Both the thickness and the outer diameter of the cups were measured and compared for each set of experimental conditions. It was found that the dimensional accuracy of cups rapidly improves by employing the ironing process and also by increasing the amount of ironing.

• Transactions of Materials Processing
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• v.19 no.4
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• pp.253-262
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• 2010

For multi-stage deep drawing process including ironing operation and biaxial forming in this study, tool developments are achieved, and the developed tool sets are applied to experimental investigations. In process and tool designs, a contact condition between intermediate blank and lower die is considered as the sequential one. In this study, the material used is cold-rolled thin sheet (SPCE) with the initial thickness of 0.4mm. From the experimental approaches, several failures such as tearing, localized thickening and thinning, are observed. To solve these failures, the contact surface on the lower die is modified. As the experimental results by applying the modified lower die, it is investigated that the failures are not occurred, and the excessive deformation behavior due to the thinning and thickening effects are decreased. Furthermore, the thickness distributions on the major axis and the minor axis of each intermediate blank are investigated to be already satisfied the target (ironing) thickness, respectively. By this systematic approach, it is confirmed that the experimental results show good agreements with the designed and required configuration of each deformed and final products.

• Transactions of Materials Processing
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• v.22 no.3
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• pp.133-142
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• 2013

Recently, electric vehicles and hybrid cars are being promoted as alternatives to reduce automobile emissions. Generally, thin sheet materials such as aluminum alloy AA300X and cold-rolled steel sheet such as JIS-G-3141 are used for the container for the lithium-ion secondary batteries. In this study, a multi-stage deep drawing process is used to produce a rectangular cup from thin stainless steel sheet material, SUS409L, with an initial blank thickness of 0.4mm for the battery container application. Numerical simulations of the first through the fifth stages for the multi-stage deep drawing with thin SUS409L sheet were conducted using LS-Dyna3D Implicit/Explicit. Special consideration was given to the deformation characteristics due to the normal anisotropy of the sheet material. The numerical simulations were conducted with both isotropic properties and the anisotropic properties of the initial blank material. An unexpected forming failure, barreling in the bottom region of the deep drawn rectangular cup, was observed. This failure mode can be avoided by additional ironing thickness control during the process.