Application of die angle deep drawing molding method to hydromechanical deep drawing method

Dies with die/pressure plate angle which are among metal sheet forming processes and has attracted attention in recent years and methods of hydromechanical deep drawing process have been developed by conducting experimental and numeric analysis. In the present study, hydromechanical deep drawing process with die/pressure plate angle was applied by combining two metal sheet forming processes. The present study investigated the effects of die/ pressure plate angle, die/punch radius, pressure plate force and chamber pressure; limit drawing ratio(β), changes in wall thickness of die and punch force for sheet material formed. Deep drawability of 0.9 mm thick DIN EN 10130-1999 metal sheet was investigated an experimental and numeric manner in the present study. In order to achieve this, punch with a 30 mm diameter was processed at R=6 mm, R=8 mm and R=10 mm of die/punch radii and 00, 2,50, 50, 100, 12,50, and 150 of die/ pressure plate angle. Chamber pressure was applied as 6 Mpa, 8 Mpa, and 10 Mpa of pressure. Variables were used as 1964.95 N, 5882.78 N, and 9507.64 N of pressure plate forces in order to ensure control when metal sheet was flowing into die. Punch rate was taken as constant in experimental and numeric studies. The punch force occurring during deep drawing process was measured in 10-1 second interval with the aid of load cell. Wall thickness change of container in experimental samples was identified by a micrometer with 10-4 mm of precision. Numeric analysis was performed by using ANSYS 15.0 software. Experimental design was carried out by using Taguchi experimental design method according to L18 orthogonal array. While the lowest value of limit drawing ratio was β=2.4, the highest value was β=2.6; while the lowest thickness of area in thickness distributions for 0.9-mm thick metal sheet was 0.7635 mm, the highest thickness of area was 0.9970 mm. Optimum value for pressure plate and die pressure was the second level of these parameters. Punch force was identified to increase when die/pressure plate angle increased; however, wall thickness change decreased. Limit drawing ratio was determined to increase in parallel, based on increased punch radius value.