Analyzing the effect of reducing sheet metal thickness on the formability of high strength steels

The household appliances sector is approaching the production amount of 3000000 units/year. A large number of sheet metal parts are combined to form products in white goods such as washing machines, refrigerators, ovens, and televisions. Due to the high production number of sheet metal parts used in the construction of machines, it has gained great importance to design sheet metal molding, production methods, sheet material dimensions to be used, and appropriate sheet metal mold design. On the other hand, the high annual production numbers affect the unit costs of the parts used. One of the most important factors affecting the unit cost is the type of material used and the thickness of the material. In the present thesis, the front cover part of the drum used in the washing machine was examined. Sheet thinning studies were carried out on three different material types ANSI 430, DX54D, DC04 of the front cover part. Sheet thicknesses are reduced from 0.5 mm to 0.37 mm; Formability analysis of ANSI 430, DX54D, DC04 materials, thinning analysis, wrinkling analysis, edge crack analysis, spring-back analysis, analysis of forces that will occur on the mold were evaluated. As a result, the studies could be carried out without any damage to the shaping processes for every thickness and material type. It has been determined that as the sheet thickness decreases, the yield and tensile strength, elongation, and hardness increase, the formability becomes more difficult, the amount of thinning in the sheet, spring back and edge cracks increase. As a result of the analysis, it was decided to use 0.37 mm thick AISI 430 material as the front cover material. Thus, 212 gr when the annual production amount is calculated over 3000000 pieces/year and 636000 kg per year were saved in conditions where we experience a worldwide shortage of raw materials. This value has been calculated as approximately $849060 per year for the manufacturer.