Formability Analysis of 6063 Al Alloy for Deep Drawn Cylindrical Cups with Constant and Progressive Blank Holding Force

International Journal of Mechanical Engineering
© 2017 by SSRG - IJME Journal
Volume 4 Issue 5
Year of Publication : 2017
Authors : A. Chennakesava Reddy
pdf
How to Cite?

A. Chennakesava Reddy, "Formability Analysis of 6063 Al Alloy for Deep Drawn Cylindrical Cups with Constant and Progressive Blank Holding Force," SSRG International Journal of Mechanical Engineering, vol. 4,  no. 5, pp. 15-21, 2017. Crossref, https://doi.org/10.14445/23488360/IJME-V4I5P105

Abstract:

In this present work, a statistical approach based on Taguchi techniques and finite element analysis were adopted to determine the influence of temperature, strain rate coefficient of friction and blank holder velocity on the formability of cylindrical cups from 6063 Al alloy using warm deep drawing process. The successful conical cups of 1.5mm blank thickness were obtained with operating conditions of 300oC, 0.1 s-1, strain rate temperature; 0.1, coefficient of friction; and 0.13 mms-1, blank holder velocity.

Keywords:

6063 Al alloy, cylindrical cups, formability, finite element analysis, Taguchi, temperature, strain rate, coefficient of friction, blank holder velocity.

References:

[1] H. Ohsawa and M. Ikeda, ―Tensile Ductility and Deep Drawability of Rate-Dependent Sheet Materials, Journal of Materials Processing Technology, vol. 38, pp. 703 -722, 1993.
[2] A. C Reddy, T. K. K. Reddy and M. Vidya Sagar, ―Experimental characterization of warm deep drawing process for EDD steel, International Journal of Multidisciplinary Research & Advances in Engineering, vol. 4, no. 3, pp.53-62, 2012.
[3] J. Cao and M. C. Boyce, ―A predictive tool for delaying wrinkling and tearing failures in sheet metal forming, ASME Journal of Materials Technology, vol. 119, pp.354–65, 1997.
[4] A. C. Reddy, ―Finite element analysis of reverse superplastic blow forming of Ti-Al-4V alloy for optimized control of thickness variation using ABAQUS, Journal of Manufacturing Engineering, vol. 1, no.1, pp.06-09, 2006.
[5] S. A. Meguid and M. H. Refaat, ―Finite element of the deep drawing process using variational inequalities. Finite Elements in Analysis and Design, vol. 28, pp.51–57, 1997.
[6] A. C. Reddy, ―Evaluation of local thinning during cup drawing of gas cylinder steel using isotropic criteria, International Journal of Engineering and Materials Sciences, vol. 5, no. 2, pp. 71-76, 2012.
[7] D. A. Aderibigbe and O. Sowole, ―Effects of Temper Annealing Temperatures and Times on the Mechanical Properties of Cold-Worked Al 1200, Journal of Engineering Research, vol. 1, no.1, pp. 49-59, 1989.
[8] A. C. Reddy, ―Homogenization and Parametric Consequence of Warm Deep Drawing Process for 1050A Aluminum Alloy: Validation through FEA, International Journal of Science and Research, vol. 4, no. 4, pp. 2034-2042, 2015.
[9] J. B. Kim, J. W. Yoon and D. Y. Yang, ―Investigation into the wrinkling behaviour of thin sheets in the Cylindrical cup deep drawing process using bifurcation theory, International journal for Numerical Methods in Engineering, vol. 56, no.12, PP. 1673-1705, 2003.
[10] A. C. Reddy, ―Parametric Optimization of Warm Deep Drawing Process of 2014T6 Aluminum Alloy Using FEA, International Journal of Scientific & Engineering Research, vol. 6, no.5, pp. 1016-1024, 2015.
[11] R. Cada, ―Evaluation of strain and material flow in sheet metal forming, Journals of Materials Processing Technology, vol. 138, pp.170-172, 2003.
[12] A. C. Reddy, ―Finite Element Analysis of Warm Deep Drawing Process for 2017T4 Aluminum Alloy: Parametric Significance Using Taguchi Technique, International Journal of Advanced Research, vol. 3, no. 5, pp. 1247-1255, 2015.
[13] A. Nader, ―Forming of Aluminum alloys at elevated temperatures-part1: Material characterization, International Journal of Plasticity, vol. 22, pp. 314-341, 2006.
[14] A. C. Reddy, ―Parametric Significance of Warm Drawing Process for 2024T4 Aluminum Alloy through FEA, International Journal of Science and Research, vol. 4, no. 5, pp. 2345-2351, 2015.
[15] A. Wifi and A. Mosallam, ―Some aspects of blank-holder force schemes in deep drawing process Journal of Achievements in Materials and Manufacturing Engineering, vol. 24, no. 1, pp. 315−323, 2007.
[16] A. C. Reddy, ―Formability of High Temperature and High Strain Rate Superplastic Deep Drawing Process for AA2219 Cylindrical Cups, International Journal of Advanced Research, vol. 3, no. 10, pp. 1016-1024, 2015.
[17] B. Ukota, ―Sheet Metal Forming Process and Die Design, Industrial Press, pp.69-72, 2004.
[18] C. R Alavala, ―High temperature and high strain rate superplastic deep drawing process for AA2618 alloy cylindrical cups, International Journal of Scientific Engineering and Applied Science, vol. 2, no. 2, pp. 35-41, 2016.
[19] F. Ayari, T. Lazbhab and E. Bayraktar, ―Parametric Finite Element Analysis of square cup drawing, Archives of computational material science and surface engineering, vol. 1, no. 2, pp. 106-111, 2009.
[20] C. R Alavala, ―Practicability of High Temperature and High Strain Rate Superplastic Deep Drawing Process for AA3003 Alloy Cylindrical Cups, International Journal of Engineering Inventions, vol. 5, no. 3, pp. 16-23, 2016.
[21] E. Onate and O. C. Zienkiewicz, ―A viscous formulation for the analysis of thin sheet metal forming, International Journal of Mechanical Sciences, vol. 25, no. 5, pp. 305-335, 1983.
[22] C. R Alavala, ―High temperature and high strain rate superplastic deep drawing process for AA5049 alloy cylindrical cups, International Journal of Engineering Sciences & Research Technology, vol. 5, no. 2, pp. 261-268, 2016.
[23] S. Toros, F. Ozturk and K. Ilyas, ―Review of warm forming of aluminum–magnesium alloys, Journal of Materials Processing Technology, vol. 207, no.1-3, pp. 1–12, 2008.
[24] C. R Alavala, ―Suitability of High Temperature and High Strain Rate Superplastic Deep Drawing Process for AA5052 Alloy, International Journal of Engineering and Advanced Research Technology, vol. 2, no. 3, pp. 11-14, 2016.
[25] C. R Alavala, ―Effect of Temperature, Strain Rate and Coefficient of Friction on Deep Drawing Process of 6061 Aluminum Alloy, International Journal of Mechanical Engineering, vol. 5, no. 6, PP. 11-24, 2016.