ISSN: 2250-3005 - ijcer

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International Journal Of Computational Engineering Research (ijceronline.com) Vol. 2 Issue. 8Finite Element Simulation of Single Stage Deep Drawing Process forDetermining Stress Distribution in Drawn Conical ComponentShishir Anwekar 1 , Abhishek Jain 21, 2Mechanical Engineering, University Institute of Technology, Barkatullah University, Bhopal, IndiaAbstract:To avoid the expensive and difficult experiments, modern manufacturing is based on the analysis of forming processes innumeral atmosphere before the actual production set-up. In the presented work , the single stage deep drawing process of thinwalled, mild steel, conical back plate of radial impeller of blowers is approached by means of a finite element analysis. Simulationof the drawing process for determining stress distribution in the drawn component for a particular displacement is explained in thepresented work. The distribution of stress in the drawn component is obtained. The study was conducted by using ANSYS12.0, inwhich, two models have been tested. Both models constructed solely out of axisymmetric, quad 4 node, PLANE 42 elementswhich have been used to simulate the drawing process of drawing quality mild steel IS2062 grade. The experimental analysis iscarried out on two different flat plates having thickness 3 mm and 5 mm from which the conical back plate is manufactured. Th isstudy will be beneficial to the tool designer and the manufacturers doing work in this fieldKey words: Deep drawing , Finite element simulation, Forming, Manufacturing, Sheet metal, Tool designer,.1. IntroductionCasting, machining, welding and metal forming are the main methods of manufacturing .Sheet metal forming is animportant manufacturing process for producing a large variety of automotive parts and aerospace parts as well as consumerproducts. Deep drawing is a forming process involving variety of material flo w conditions. With the developments in thetechnology the design of deep drawing is an art than science still today .It depends on the knowledge and experience of the d esignengineer only. The selection of various parameters is still based on trial and error methods [1],. The use of numerical simulationcould contribute towards the development and optimization of the process, leading to considerable economic and technical gain s.Deep drawing is one of the most important sheet metal forming processes in which a 2-d part is shaped into a 3-d part bydeep drawing. In deep drawing, a flat blank of sheet metal is shaped by the action of a punch forcing the metal into a die cavity.The application of the finite element method to the numerical simulation of the deep -drawing process has evolved in a significantway in the course of the last few years. Many of the problems associated with numerical simulation of this process have beensolved or at least are better understood. Reviewing the various literature available on simulation of drawing, it is understood th atmost of the research work are focused on drawing of cylindrical product. Relatively a few research work has been done for fin iteelement simulation conical product. The conical shaped product made on hydraulic power press was extensively used in theengineering and day today life.In the study of Saad Theyyab Faris [1], a numerical procedure was proposed for the design of deep d rawing process usingfinite element method through program code ANSYS 5.4 simplified 2 -D axisymmetric model of cylindrical cup are beendeveloped. M. Afteni et al., [2] put forward that the increasing demands for small devices which have multiple applicat ions inautomotive industry, in chemical industry but also in medicine leads to new approaches concerning both the simulation and theexperimental analysis of the material forming processes. They presented the experimental and numerical studies regarding t hemicro-deep drawing of Nickle sheets. According to Dr.Sc. Amra Tali ikmi et al,[3] deep drawing is a process for shaping flatsheets into cup-shaped articles without fracture or excessive localized thinning. Their paper describes the use of ABAQUS finit eelement code in a single stage sheet metal forming simulation on rectangle cup deep drawing. They suggested that the mainobjective of numerical simulation of the forming process is to reduce the development time of a new product. Eric T. Harpell et al.,.[4] modelled various tooling geometries by using finite element analysis. But in their study they worked on aluminium shee t.L.F. Menezes et al. [5] presented a three-dimensional mechanical model for the numerical simulation of the deep-drawing process.The model takes into account the large elastoplastic strains and rotations that occur in the deep -drawing process. According toAbdolhamid Gorji .[6] forming conical parts is one of the complex and difficult fields in sheet-metal forming processes.||Issn 2250-3005(online)|| ||December||2012|| Page 229
International Journal Of Computational Engineering Research (ijceronline.com) Vol. 2 Issue. 8Simulation of elastic-plastic behavior of mild steel sheet is carried out with non-linear condition to gain accurate and criticalunderstanding of sheet forming process byAccording to Laxmiputra M Nimbalkar et al. [7]2. Process DescriptionDuring the process a piece of sheet metal is clamped between the die and the blank holder. A force is applied to the blankholder to prevent wrinkling of the sheet and to control the material flow during the deformation. When the punch is pushed in to thedie cavity the sheet deforms plastically and thereby it takes the specific shape of the tools.[8] An example of such a deep drawingpart is given in figure 1.Fig. 1: Set up of a drawing tooling for making conical shaped product from a flat plate3. Outline Of Finite Element AnalysisFinite element analysis (FEA) has become commonplace in recent years. Numerical solutions to even very complicatedstress problems can now be obtained routinely using FEA. Finite element analysis is a simulation technique which evaluate s thebehaviour of components, equipments and structures for various loading conditions. It is a numerical method , that is used in theanalysis of complex mechanical and structural problems. It is used to obtain numerical solutions and can be applied over a widerange of objective functions and over a wide range of loading conditions. The method can be used for analysis of static problemsand dynamic problems and can even be used to analyze linear systems and non-linear systems.A linear system is a type of system where a linear relation-ship exists between the force and deflection and these systemsdo not take plastic deformation in account. A non-linear system is a type of system that takes plastic deformation into account andcan allow testing all the way up to the points of fracture. FEA can be applied to problems that involve heat loss, fluid flow andeven electric potential. Due to this wide range of application, the method is very popular. The method is used in the analysis ofmany complex two dimensional problems, but can also be applied for problems involving three-dimensions. As problems becomemore complex with finite element analysis, they can take longer to solve. Computers are used to solve complex finite elementproblems and a wide range of finite element analysis software exists today e.g. LUSAS, ABAQUS, ANSYS etc..The method works by taking a problem and modeling it into smaller elements through the use of nodes and elements.Physical and geometric properties are assigned to the elements and loads and displacements are applied to the nodes. From that, afinite element analysis is carried out in an attempt to earn numerical values.Fig. 2: Finite Element Mesh structure||Issn 2250-3005(online)|| ||December||2012|| Page 230
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