The effect of temperature on drawability of circular and square sheet metal drawing / Muhammad Basril Muhammad Asri

Muhammad Basril, Muhmmad Asri (2022) The effect of temperature on drawability of circular and square sheet metal drawing / Muhammad Basril Muhammad Asri. Masters thesis, University of Malaya.

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Abstract

Sheet metal drawing is a well-known process used in today's industries, and the most significant challenge encountered throughout this process is product quality. In sheet metal drawing, product quality is vital and based on current research trends, varying the process temperature improves the quality. This study focuses on the influence of tooling temperature on the drawability of sheet metal drawn circular and square cups with various blank sizes. Following that, an evaluation of the impact of different process parameters on the warm sheet metal drawing was carried out. Consequently, the drawability of circular and square cups will be analysed by comparing experimental and finite element analysis (FEA) data. The Taguchi method L9 (34 ) array experiment design was used to plan the process parameters and the experimental design in this study. The experimental procedures were prepared with the experimental apparatus's consideration. The experimental setup apparatus for circular and square cups, which includes a die set, heater, thermocouple, hydraulic pump and cylinder, is then put through a series of tests. Firstly, circular cups of aluminium 6065 (AL6065), mild steel (MS), and stainless steel 304 (SS304) were drawn from the blank with diameters of 60 mm, 65 mm, and 70 mm. Next, the same material was drawn for square cups with a blank diameter of 45 mm, 50 mm, and 55 mm. Both cup shape is tested at room temperature, then at temperatures of 100°C, 150°C, and 200°C. The response factors consist of limiting drawing ratio (LDR), average cup height and thickness distribution were collected from room and warm temperatures. First, these outputs were analysed using the analysis of variance (ANOVA) to determine their effect on warm sheet metal drawing. Then, the sheet metal drawing process is simulated using ABAQUS/CAE software to predict the drawn cup thickness distribution. Eventually, the simulated data will be compared with the experiment for verification. From the ANOVA analysis, the blank material had the most significant impact on the drawability of warm sheet metal drawn circular cups, followed by the blank size, heating technique, and heating temperature. The optimal parameter was 65 mm of the AL6065 blank with a heating temperature of 150°C applied to the punch. On the other hand, the drawability of warm sheet metal drawn square cups was substantially impacted by the blank size, followed by the material, heating technique, and heating temperature. The optimal parameter was 45 mm of the AL6065 blank with a heating temperature of 150°C applied to the punch.

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