The Effect of Die Geometry on Cup Damages in Cold Deep Drawing of Rectangular Cups

Year 2022, , 340 - 350, 30.12.2022

Cebeli Özek

https://doi.org/10.46460/ijiea.1169005

Abstract

Deep drawing is the flow of sheet into the die cavity by applying punch force. In deep drawing, cups have been produced by pushing the sheet from the center part into the die cavity by punches to bring the sheet into the desired cup between flat thin layers. Higher drawing ratios cannot be obtained in deep drawing cups due to neck formation or cracking in the corner radii of the cup. For this, it is important to determine the appropriate parameters correctly for the deep drawing to be successful. In this article, the effects of die geometry on cup wall thickness and its damages were determined by giving angles to the upper surface of the die and the lower surface of the blank holder in deep drawing of rectangular cups. Thus, angles of 0°, 3°, 6°, and 9° were given to the die upper surface/blank holder lower surface. The study was carried out at a constant 1800 daN blank holder force and a constant 4 mm/s punch speed. In the deep drawing, the gap between the die/punch was 1.2 mm, and the bottom of punch and edge radii and the die throat radii were used fixed at 6 mm. St37 steel with a thickness of 1 mm was used in this study. The wall thicknesses were measured using a Mitutoyo LH-600E precision linear measuring device with a precision of 0.001 point contact. It was determined that the wall thickness of the cups increased as the cup heights increased, the maximum wall thickness occurred at the corners of the lower parts of the cups and was 0.373 mm. The region most affected by plastic deformation is the lower part of the cup. Maximum compressive and tensile forces occur in this region due to deformation hardening and therefore maximum stress and hardness have occurred in this region. The maximum hardness was measured in the region of the bottom of the cup and as 61.4 HRC. The minimum hardness was measured in the top region of cup. It was observed that the hardness decreased further towards the upper rim of the cup and was 43.8 HRC. The average hardness value was determined as 53.1 HRC. As a result, it has been determined that the die geometry has a significant effect on cup wall thickness changes and cup damages by giving angles to the upper surface of the die and the lower surface of the blank holder in cold deep drawing of rectangular cups.

Keywords

Cup Damage, Deep Drawing, Limit Drawing Ratio, Rectangular Cups

Dikdörtgen Geometriye Sahip Kapların Soğuk Derin Çekilmesinde Kalıp Geometrisinin Kap Hasarları Üzerindeki Etkisi

Abstract

Derin çekme, zımba kuvveti uygulanarak sac malzemenin kalıp boşluğuna akışıdır. Derin çekmede, düz ince tabakalar arasında sacı istenen şekle getirmek için zımba kullanılarak sacı merkez kısmından kalıp boşluğuna iterek kaplar üretilmektedir. Derin çekilmiş kaplarda kabın köşe yarıçaplarında boyun oluşumu veya çatlamaların oluşması nedeniyle daha yüksek çekme oranları elde edilememektedir. Bunun için derin çekme işleminin başarılı olmasında uygun işlem parametrelerinin doğru seçilmesi önemlidir. Bu makalede, dikdörtgen geometriye sahip kapların derin çekilmesinde matris üst yüzeyine ve pot çemberinin alt yüzeyine açılar verilerek matris geometrisinin, kap kesit incelmeleri ve hasarları üzerinde olan etkileri tespit edilmiştir. Bunun için matris üst yüzeyine/pot çemberi alt yüzeyine 0°, 3°, 6° ve 9°’lik açılar verilmiştir. Pot çemberi kuvveti sabit 1800 daN ve stampa hızı da sabit 4 mm/s olarak uygulanmıştır. Derin çekme işlemlerinde, matris/stampa arası boşluk 1.2 mm, stampa uç ve kenar radyüsleri ile matris ağız yarıçapları 6 mm alınmıştır. Çalışmada kalınlığı 1 mm olan St37 çeliği kullanılmıştır. Cidar kalınlıkları Mitutoyo LH-600E hassas lineer ölçüm cihazında 0.001 hassasiyetinde nokta temaslı olarak ölçülmüştür. Kap yükseklikleri artıkça kaplardaki cidar incelmelerinin arttığı, maksimum incelmenin kabın alt kısımlarındaki köşelerde meydana geldiği ve bu değerin 0,373 mm olduğu tespit edilmiştir. Plastik deformasyonun en çok etkilediği bölge kap alt bölgesidir. Bu bölgede deformasyon sertleşmesi nedeniyle maksimum basma ve çekme kuvvetleri oluşmakta ve dolayısıyla maksimum gerilme ve sertlik bu kısımda meydana gelmiştir. Maksimum sertlik kabın tabanının olduğu bölgede ve 61.4 HRC olarak ölçülmüştür. Minimum sertlik kap üst bölgesinde ölçülmüştür. Kabın üst ağız kısımlarına doğru sertliğin daha da düştüğü ve 43.8 HRC olduğu görülmüştür. Ortalama sertlik değeri ise 53.1 HRC olarak tespit edilmiştir. Sonuç olarak, dikdörtgen geometriye sahip kapların soğuk derin çekilmesinde, matris üst yüzeyine ve pot çemberinin alt yüzeyine açılar verilerek kalıp geometrisinin, kap cidar kalınlık değişimleri ve kap hasarları üzerinde önemli bir etkisinin olduğu tespit edilmiştir.

Keywords

Derin Çekme, Dikdörtgen Kaplar, Kap hasarları, Limit Çekme Oranı

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