Numerical Simulation of Hydro-mechanical Deep Drawing - A Study on the Effect of Process Parameters on Drawability and Thickness Variation

Hydro-mechanical deep drawing is a process for producing cup shaped parts with the assistance of a pressurized fluid. In the present work, numerical simulation of the conventional and counter pressure deep drawing processes has been done with the help of a finite element method based software. Simulation results were analyzed to study the improvement in drawability by using hydro-mechanical processes. The thickness variations in the drawn cups were analyzed and also the effect of counter pressure and oil gap on the thickness distribution was studied. Numerical simulations were also used for the die design, which combines both drawing and ironing processes in a single operation. This modification in the die provides high drawability, facilitates smooth material flow, gives more uniform thickness distribution and corrects the shape distortion.