An investigation on the effects of the process parameters of hydro-mechanical deep drawing on manufacturing high-quality
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ORIGINAL ARTICLE
An investigation on the effects of the process parameters of hydro-mechanical deep drawing on manufacturing high-quality bimetallic spherical-conical cups S. Yaghoubi 1 & F. Fereshteh-Saniee 1 Received: 23 March 2020 / Accepted: 20 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract This paper aims to analytically, experimentally, and numerically study the hydro-mechanical deep drawing (HMDD) process of bimetallic specimens. The blank included aluminum and steel sheets used to produce double-layer conical-spherical cups. The punch geometry, maximum fluid pressure, pre-bulge pressure, layer arrangement, and the drawing depth were the process parameters investigated in this article. Two criterions based on the thickness strain and thickness variation were used to assess the effects of these variables on the quality of the final product. The results of the analytical modeling and numerical simulations were verified by comparing with the related experimental data. Different outcomes were in acceptable agreement with each other. Based on the findings obtained, by increasing the fluid pressure up to 15 MPa, the quality of the final product was enhanced. Moreover, by applying the pre-bulge pressure in the HMDD process, the separation between the layers as well as the thickness variation decreased. The highest improvements in the values of the maximum thickness strain and thickness variation in the current investigation were gained to be 57% and 68%, respectively, in comparison with the traditional state of the deep drawing process. Keywords Hydro-mechanical deep drawing . Spherical-conical bimetallic cups . Control of pre-bulge pressure . Fluid pressure . Thickness variation
1 Introduction In a metal forming process, the particular shape of a solid part is changed permanently without changing its mass, volume, and composition [1]. Sheet metal forming is one of the most important types of metal forming process and plays a major role in various industries [2]. Hydroforming is one of modern approaches in sheet metal forming and has been widely utilized in different applications. In this operation, in addition to mechanical forces exerted by the punch, the fluid pressure is also applied in different ways to form the final product. One of the first applications of this method in industries was manufacturing the car and aircraft body parts, where * F. Fereshteh-Saniee [email protected]; [email protected] S. Yaghoubi [email protected] 1
Department of Mechanical Engineering, Faculty of Engineering, Bu-Ali Sina University, Hamedan 65178, Iran
significant improvements were achieved in this field [3]. Although several researches have been conducted in recent years on sheet hydroforming, the development and application of this technique in various industries was lower than that of the tube hydroforming [4]. Forming complex parts, providing higher dimensional accuracy due to reduction of spring-back, desirable surface uniformity without needing any complex die, appropriate th
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