A Finite Element Analysis of Cold Deep Drawing of Al Alloy Considering Friction Condition and Corner Design of Plunger

Abstract

This study presents an innovative methodology that integrates experimental investigations with finite element simulations to ascertain the validity and reliability of Al 3104 sheet metals during cold deep drawing. Focusing on the nose plunger radius and coefficient of friction at a fixed speed and temperature (25 °C), five different scenarios are utilized to simulate the optimum parameters. Through a detailed strain history analysis from simulations, the initiation of bending in the corner is precisely identified, with a validation achieved through a strain analysis obtained via digital image correlation. The study delves into the influence of strain and strain rate on the microstructures and mechanical properties near the corner region. It highlights the superior efficacy of strain-based criteria in characterizing deformation behavior. Notably, the strain distributions during the onset of bending and severe bending align remarkably well with the established simulation data. In brief, this work introduces an integrated approach that harmoniously combines computational simulations with empirical observations, resulting in significant ramifications for precisely comprehending and forecasting the strain distribution in metal forming operations.