Determination of Process Parameters in Multi-Stage Hydro-Mechanical Deep Drawing by FE Simulation

In this work, analysis has been carried to simulate manufacturing of a near hemispherical bottom part with large depth by hydro-mechanical deep drawing with an aim to reduce the number of forming steps and to reduce the extent of thinning in the dome region. Inconel 718 has been considered as the material due to its importance in aerospace industry. It is a Ni-based super alloy and it is one of the most widely used of all super alloys primarily due to large-scale applications in aircraft engines. Using Finite Element Method (FEM), numerical simulations have been carried out for multi-stage hydro-mechanical deep drawing by using the same draw ratios and design parameters as in the case of conventional deep drawing in four stages. The results showed that the minimum thickness in the final part can be increased significantly when compared to conventional deep drawing. It has been found that the part could be deep drawn to the desired height (after trimming at the final stage) without any severe wrinkling. Blank holding force (BHF) and peak counter pressure have been found to have a strong influence on thinning in the component. Decreasing the coefficient of friction has marginally increased the minimum thickness in the final component. By increasing the draw ratio and optimizing BHF, counter pressure and die corner radius in the simulations, it has been found that it is possible to draw the final part in three stages. It has been found that thinning can be further reduced by decreasing the initial blank size without any reduction in the final height. This reduced the draw ratio at every stage and optimum combination of BHF and counter pressure have been found for the 3-stage process also.