Hydrodynamic Deep Drawing Assisted by Radial Pressure of Al/St Bimetal Square Cups

In this research, forming of Bimetal (Al/St) square cups in hydrodynamic deep drawing assisted by radial pressure process has been studied aiming to investigate the parameters and their effects on the thickness of cups. At first, using finite element simulations by Abaqus software, different pressure paths were tried to form the square cup, and experiments were utilized to validate the results. The results showed that lower maximum pressure and lower punch velocity lead to tearing on the sheet contact area with the punch tip. Also, they demonstrated that at higher levels of pressures and punch velocities, the wall thickness distribution of the square cups depends on the pressure path. By applying the pressure path with the desired maximum amount, the square cups with high deep drawing ratio were formed. In the next step, the effect of several important parameters in terms of the desired pressure path was investigated using design of experiments, and the results were interpreted using ANOVA. Among the studied factors, direct effect of the punch tip radius and the interaction of the layers layout and thickness ratio had a significant effect on the minimum thickness of square cups. Finally, the optimal factor values were also obtained.