Numerical and Experimental Investigation of Deep Drawing Process in Square Section of Single-Layer and Two-Layer Sheet

Deep drawing of two-layer sheet is a suitable way to achieve product with a desired shape and desired properties in sheet metal forming technology. Control of deep drawing parameter such as thinning is the most important challenge in this process. The most difficult part of this challenge is differences in material properties and geometry of each layer. In this paper, numerical approach has been exploited to plan and control of two layer deep drawing process. For this purpose, the three-dimensional (3D) finite element has been used. ST14– Al1100 (A.I. and S.I. lay-up) were selected as materials of two layer sheet metal. The results of simulation have been validated with experiments. Based on numerical study, effect of process parameters on the percentage of thinning, maximum plastic strain, rupture, required forming force and blank holder force (BHF) has been studied. This study has also been done on one-layer sheet metal and differences between deep drawing of one-layer and two-layer sheets have been comprehensively investigated. The results showed that maximum thinning is occurred in the upper layer of die radial region as well as in the lower layer of punch radial region. Also, the maximum equivalent plastic strain in the lower layer is more than the maximum of equivalent plastic strain in the upper layer.