Numerical Investigation of the Impact of Punch Speed on the Deep Drawing of Square Aluminum Sheet Using Finite Element Method

Abstract

This study examines the Deep Drawing Process (DDP) of square aluminum sheets, emphasizing its applications across various industries, including medical devices. The process is simulated using ABAQUS finite element software, analyzing the effects of parameters like punch speed and friction on the final results. One of the important aspects of this study is the use of the Forming Limit Diagram (FLD) criterion to determine the rupture point of the sheet during the DDP. This criterion allows us to assess the deformation of the sheet and examine the possibility of predicting and preventing rupture at different stages of the deep drawing. The results obtained from the simulations show that reducing the punch speed in the DDP of aluminum leads to a greater thickness of the final part at the same depth produced. In other words, decreasing the punch speed results in an increased duration of the DDP, which aids in producing parts with greater depth. This finding is particularly important in the manufacture of components featuring intricate shapes that demand high precision. Moreover, the research results indicate that by reducing the frictional interaction between the holder and sheet, as well as increasing the frictional interaction between the sheet and die, it is possible to produce parts with greater depth and less wrinkling and tearing. This outcome suggests that optimizing lubrication conditions and appropriately designing various parts of the die can significantly enhance the final quality of the produced components and the efficiency of the DDP.