Deformation law research and process optimization of thin-walled sink in deep drawing
To solve the problems of high difficulty and high cost in the mold manufacture and mold testing of the thin-walled sink with complicated and asymmetric geometrical shape formed by three-times deep drawing process,when the multi-pass deep drawing process was adopted to the sink,the deformation law of sheet metal was studied,and the deep drawing process were optimized.Dynaform finite element analysis software was used to carry out the numerical simulation analysis on the first sequence,the second sequence and third se-quence of deep drawing for the thin-walled sink.The influence laws of key process parameters on the forming results were studied and the optimal process parameters were obtained.Finally,the process scheme was verified through the deep drawing experiments.According to the process optimization scheme,the optimal process parameters were obtained.The first deep drawing sequence:the blank holder force is maintained at 40 kN from 0 s to 0.01 s,and the blank holder force increases linearly from 40 kN to 500 kN from 0.01 s to the end of deep drawing;the friction factors between punch,die,blank holder and sheet are 0.2,0.05,0.05,respectively,and the die clearance is 0.66 mm.The second deep drawing sequence:the friction factors between punch,die,blank holder and sheet are 0.15,0.1,0.1,re-spectively,and the blank holder force is 500 kN.The third deep drawing sequence:appropriate drawbead arrangement and resistance value are adopted.The experimental results show that the thinning amount of the thin-walled sink can be effectively controlled by focusing on regulating and controlling different deep drawing process parameters in different deep drawing sequences.
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