Micro-hydromechanical deep drawing of metal cups with hydraulic pressure effects

doi:10.1007/s11465-018-0468-z

Front. Mech. Eng.

2018, Vol. 13

Issue (1) : 66-73 https://doi.org/10.1007/s11465-018-0468-z

RESEARCH ARTICLE

Micro-hydromechanical deep drawing of metal cups with hydraulic pressure effects

Liang LUO¹, Zhengyi JIANG^1,³(

), Dongbin WEI², Xiaogang WANG³, Cunlong ZHOU³, Qingxue HUANG³

¹. School of Mechanical, Materials, Mechatronic, and Biomedical Engineering, University of Wollongong, Wollongong, NSW 2522, Australia
². School of Electrical, Mechanical, and Mechatronic System, University of Technology, Sydney, NSW 2007, Australia
³. School of Materials Science and Engineering, Taiyuan University of Science and Technology, Taiyuan 030024, China

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Abstract

Micro-metal products have recently enjoyed high demand. In addition, metal microforming has drawn increasing attention due to its net-forming capability, batch manufacturing potential, high product quality, and relatively low equipment cost. Micro-hydromechanical deep drawing (MHDD), a typical microforming method, has been developed to take advantage of hydraulic force. With reduced dimensions, the hydraulic pressure development changes; accordingly, the lubrication condition changes from the macroscale to the microscale. A Voronoi-based finite element model is proposed in this paper to consider the change in lubrication in MHDD according to open and closed lubricant pocket theory. Simulation results agree with experimental results concerning drawing force. Changes in friction significantly affect the drawing process and the drawn cups. Moreover, defined wrinkle indexes have been shown to have a complex relationship with hydraulic pressure. High hydraulic pressure can increase the maximum drawing ratio (drawn cup height), whereas the surface finish represented by the wear is not linearly dependent on the hydraulic pressure due to the wrinkles.

Keywords micro-hydromechanical deep drawing microforming size effects lubrication Voronoi

Corresponding Author(s): Zhengyi JIANG

Just Accepted Date: 13 September 2017 Online First Date: 31 October 2017 Issue Date: 23 January 2018

Cite this article:

Liang LUO,Zhengyi JIANG,Dongbin WEI, et al. Micro-hydromechanical deep drawing of metal cups with hydraulic pressure effects[J]. Front. Mech. Eng., 2018, 13(1): 66-73.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-018-0468-z
https://academic.hep.com.cn/fme/EN/Y2018/V13/I1/66

Fig.1 Microstructures of the three groups of annealed sheets. (a) H975; (b) H1050; (c) H1100

Fig.2 (a) Sketch of the MHDD system; (b) the normal model

Fig.3 Voronoi models for different blanks. (a) H975; (b) H1050; (c) H1100

Fig.4 The open and closed lubricant pocket models under different hydraulic pressures: (a) 5–10 MPa; (b) 15–20 MPa; (c) 25–30 MPa; (d) ultra-high hydraulic pressures

Fig.5 Relationship between the hydraulic pressure and the critical radius

Tab.1 Friction coefficients

Fig.6 Drawing forces of H975

Fig.7 Drawn cups with H975 sheets under different hydraulic pressures

Fig.8 Simulated drawn cups with H1100 sheets under different hydraulic pressures

Fig.9 Drawn cups with different blanks under 30 MPa hydraulic pressure

Fig.10 Wrinkle index values from simulation results. (a) Wrinkle index of R_a; (b) wrinkle index of R_t

Fig.11 Drawn cups with H975 sheets under (a) 30 MPa and (b) 200 MPa hydraulic pressures

Fig.12 Drawn cups with H975 sheets under different hydraulic pressures: (a) H975 10 MPa; (b) H975 30 MPa

Fig.13 The PV value differences of the drawing process with H975 sheets

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