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Die Design in Drawing with Drawbeads and Spacers

Advaith Narayanan, .
http://rave.ohiolink.edu/etdc/view?acc_num=osu1570098928207621

Abstract Details

2019, Master of Science, Ohio State University, Mechanical Engineering.
Challenges faced by the automotive industry in the areas of weight reduction, fuel efficiency and crash worthiness have necessitated the increasing use of Advanced High Strength Steels (AHSS), which have a higher strength but lower formability than conventional mild steels and low carbon steels. Hence, the quality of parts formed with AHSS is of primary concern. Some of the common defects in AHSS include occurrence of splits, wrinkles and springback in the part. Drawing is a process in which a sheet metal is drawn into a die cavity by the mechanical action of the punch. It is termed as `deep drawing’ when the draw depth of the final part exceeds its width or the diameter, depending on the shape of the final part. Deep drawing (or drawing in general) finds a variety of applications like kitchen sinks, inner automotive body panels, cooking pots, beverage cans, oil pan etc. The major defects occurring in drawn parts are wrinkling and splitting due to fracture. While many publications deal with fracture issues in drawing small parts, most of the large automotive components are drawn with the tools having drawbeads in them to exert additional restraining forces. Additionally, spacers or kiss blocks are also employed to minimize elastic deflection of the dies in the press. It is important to prevent fracture in the part when using drawbeads and spacers, as failure to do so will increase the scrap production, large number of experimental die tryouts and repeated modification of drawbeads by grinding. This study aims to propose simple guidelines using FE simulations, to predict and prevent fracture and wrinkles in a drawing process containing drawbeads and spacers, thus reducing the need for experimental die tryouts and scrap production. First, the existing fracture criteria in the literature for AHSS under deformation modes of bending and superimposed bending and stretching will be explored. Subsequently, using some of the aforementioned criteria, the effect of blank optimization, spacer height and lubrication conditions on possible fracture will be investigated, using a die set built by Honda as an example. Furthermore, the effect of drawbead geometry and change in material on possible fracture and wrinkling will be investigated. Lastly, a set of guidelines based on the studies conducted will be proposed for making a defect free part which is drawn with drawbeads and spacers.
Taylan Altan, Dr. (Advisor)
Blaine Lilly, Dr. (Committee Member)
99 p.
Mechanical Engineering
Drawing; die design; drawbeads; spacers; die force; draw-in; metal flow; Blank Holder Force; wrinkling; fracture

Recommended Citations

Citations

  • Advaith Narayanan, . (2019). Die Design in Drawing with Drawbeads and Spacers [Master's thesis, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1570098928207621

    APA Style (7th edition)

  • Advaith Narayanan, .. Die Design in Drawing with Drawbeads and Spacers. 2019. Ohio State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1570098928207621.

    MLA Style (8th edition)

  • Advaith Narayanan, .. "Die Design in Drawing with Drawbeads and Spacers." Master's thesis, Ohio State University, 2019. http://rave.ohiolink.edu/etdc/view?acc_num=osu1570098928207621

    Chicago Manual of Style (17th edition)

osu1570098928207621
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This open access ETD is published by The Ohio State University and OhioLINK.