Evaluation of Draw Bead Geometry on Deep Drawing of Complex Rectangular Shape Part

Abstract

The control of blank-holder force (BHF), is one of the main parameters in deep drawing. Fracture, wrinkling and inappropriate draw-in of sheet edges on certain locations are the main defects that occur due to insufficient and not well distributed restraining force of sheet flow into die cavity by BHF. It was demonstrated that appropriate utilization of draw beads with appropriate geometry and location in die could reduce or even eliminate these defects. Achieving an optimum geometry and location of draw beads are main issues in tooling stage that would cause high cost due to trial and error. In this paper, 2D FE analyses to reach draw bead restraining Force (DBRF) for several usual draw beads geometries were performed. 3D FE analyses of deep drawing process of a rectangular automotive panel with complex and parametric geometry with the presence of draw beads were simulated by the use of ABAQUS6.9 commercial FEM package to reach an optimization of best location and also best geometry. Response surface method with full factorial case was employed for optimization. Simulation results were validated by experimental data of deep drawing.