A Spline Shape Deep Drawing using Finite Element Simulation and Experimental Work Test

Abstract

Abstract In the current research, an analysis study was conducted to process of design of spline cup drawing. Deep-drawing tools (dies and punches) were designed and manufactured to implement the experimental work required to produce a spline cup with inner dimensions are height h=3 mm, width W=9.64 mm, and diameter d=34 mm, drawn from a circular blank of a di ameter D b = 8 0 mm, and thicknes s t = 0 . 7 mm made of low carbon steel (1008-AISI). To simulate the spline shape deep-drawing process, a commercial finite element program code ANSYS 19.0 Workbench was employed. The research aims to produce the spline shape and study the effect of the punch wall curvature radius on the drawing force, thickness distribution, and effective strains across the sidewall, major and minor axis curvature of a completely drawn spline cup using experimental testing and finite element modeling. From the comparisons between the experimental and finite element results, it was shown that the numerical results of a spline cup deep-drawing are good agreement with the results of the experiment and lie within an average of (4% - 8%). The drawing force and thinning for the small punch wall curvature radius is higher than the large punch wall curvature radius. The maximum drawing force and maximum thinning with the smallest punch wall curvature radius (0.5) at the minor axis curvature of a completely drawn spline cup. The maximum effective strain with the smallest punch wall curvature radius (0.5) at the minor axis curvature region at the completely drawn spline cup rim.