Process window diagram of conical cups in hydrodynamic deep drawing assisted by radial pressure

Major defects in forming of conical cups are wrinkles and rupture.Hydrodynamic deep drawing assisted by radial pressure（HDDRP） is a sheet hydroforming process for production of shell cups in one step.In this work,process window diagrams（PWDs） for Al1050-O,pure copper and DIN 1623 St14 steel are obtained for HDDRP process.The PWD is determined to provide a quick assessment of part producibility for sheet hydroforming process.Finite element method is used for this purpose considering the process parameters including pressure path,and the blank material and its thickness.Numerical results are validated by experiments.It is shown that the sheets with less initial thickness and higher strength show better formability and uniformity of thickness distribution on final product.The results demonstrate that the obtained PWD can predict appropriate forming area and probability of rupture or wrinkling occurrence under different pressure loading paths.

Prediction of fracture limits of Ni-Cr based alloy under warm forming condition using ductile damage models and numerical method

The stretch forming and the deep-drawing processes were carried out at 300 and 673 K to determine the safe forming and fracture limits of IN625 alloy.The experimentally obtained strain-based fracture forming limit diagram(FFLD)was transformed into a stress-based(σ-FFLD)and effective plastic strain(EPS)vs triaxiality(η)plot to remove the excess dependency of fracture limits over the strains.For the prediction of fracture limits,seven different damage models were calibrated.The Oh model displayed the best ability to predict the fracture locus with the least absolute error.Though the experimentally obtained fracture limits have only been used for the numerical analysis,none of the considered damage models predicted the fracture strains over the entire considered range of stress triaxiality(0.33<η<0.66).The deep drawing process window helped to determine wrinkling,safe and fracture zones while drawing the cylindrical cups under different temperature and lubricating conditions.Further,the highest drawing ratio of 2 was achieved at 673 K under the lubricating condition.All the numerically predicted results of both stretch forming and deep drawing processes using the Hill 1948 anisotropic yielding function were found to be good within the acceptable range of error.