Analysis of Forming Complex Cup by Drawing Process

This paper aims to design and construct a deep drawing dies to produce a complex cup with eight vertices with the major diameter (41.5 mm) and the minor diameter (34.96 mm) and length (30 mm) using numerical simulation and experimental. Also, intended to study the influence of forming method on drawing load, distribution of thickness, and distribution of stress and strain along the wall of the cup were investigated. Two forming methods were used to accomplish this research. The first forming method, which is called the direct forming method in which the complex shape is performed by drawing the circular blank metal. The second forming method is called the converting method, in which the cylindrical cup is redrawn into a complex cup. The low carbon steel sheets (1008-AISI) of the thickness (0.7 mm) and diameter (80 mm) were utilized in this research. ANSYS Workbench 18.0 software in 3-D modeling was utilized to simulate the drawing processes. The results appear that the maximum punch load was with the first forming method (the complex cup is done by drawing the circular blank metal) and higher than the maximum punch load that occurred with the second forming method. The maximum thinning at cup curvature was subjected to the complex cup produced by the first method, especially in areas of convex and concave and more than the complex cups produced by the second forming method. The second forming method is the best method to produce a complex cup with the less thinning at cup curvature and more regular thickness, stress, and strains distribution.