OCTOBER 19-20, 2012 - YMCA University of Science & Technology

Proceedings of the National Conference on
Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012
INVESTIGATION AND ANALYSIS FOR THE WRINKLING
BEHAVIOUR OF DEEP DRAWN DIE SHEET METAL COMPONENT
BY USING FAST FORM
Surya Prakash 1, Dinesh Kumar 2
1, 2 Department of Mechanical Engineering, ITM University, Gurgaon, Haryana, India.
email: suryaprakash@itmindia.edu, +91-9718238577
Abstract
The manual design of any type of drawing die is complicated and tedious procedure, In spite of all precautionary
measures there are several chances of denting, cracking and wrinkling which needs to be rectified. As the
design and development of sheet metal deep drawn die is a comprehensive technique which needs accuracy in
the apprehension of working for high order and its rectification in forming process. The appearance of
dimensional deviations of shape and position, of the defects in the metal sheets that have been subjected to a cold
plastic deformation process, represents a critical problem for the specific industry, especially for the mass
production, like the machine manufacturing industry. Thus, there arises the need for development of a system for
manufacturing wrinkle free surface of deep drawn components. The complex forces act on the sheet metal blank
during drawing are so unpredictable that they are difficult to determine manually and mathematically. These
forces cause wrinkles and other defects on the surface of the wall of component. The aim of this publication is to
present the principal aspects and investigation that effect wrinkling. Firstly component 3D-modeled in CATIA
for analyzing for detecting wrinkle prone area by using fast form software. The input to software comprises of
initial graphics exchange system .Cold rolled extra deep drawing quality material of sheet metal component has
been utilize. The out put in form of results received regarding wrinkle prone area are found in closed agreement
matching with the practical results. One can therefore easily predict and detect the tendency of expected wrinkle
formation and stress distribution in any drawn component. Some methods for preventing wrinkling in deep
drawn part are also suggested.
Keywords: Wrinkles, Forming, Sheet Metal, Deep Drawing
1. Introduction
Deep drawing is a process for shaping flat sheet into cup shaped articles, without excessive localized thinning,
fracture or wrinkling. This is done by placing a blank of appropriate size over shaped die and pressing the metal
into the die punch. In production of passenger car body, motor bike components, deep-drawing is one of the
most important manufacturing processes. A usual deep-drawing die is shown in figure 1 (a). It consists of a die
cavity, a blank holder and a punch
During the deep-drawing process, the blank is clamped between die cavity and blank holder. The blank holder is
to avoid the occurrence of wrinkling and inducing required retracking force. While the punch is forming the
blank into the die cavity, blank material flows into die cavity. This effect is called material flow. In deep-drawing
processes, it is important to control material flow in order to get defect-free components [1].
Figure 1(a) Sheet metal deep drawing process
Depending upon several factors such as geometry, volume material type, deep drawing or stretch forming is used
to form sheet metals. In sheet-forming process, however, several types of failures could occur, such as rupturing,
necking, wrinkling and spring back which is undesirable [2]. Main defects in deep-drawing processes are cracks
and sidewall wrinkling, depicted in figure 1(b) & figure 1(c).
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