Study of wear on square-shaped die during deep drawing of an anisotropic sheet
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Deep drawing is a manufacturing operation widely used in manufacturing industries for producing diversified products in large numbers and for continuous production. The automobile is one among those using deep drawing for manufacturing components like automobile outer body parts and seals. Die is one of the expensive components in this operation and the quality of the die has an impact on the quality of the finished product. Die is subjected to severe mechanical and tribological conditions due to sliding of sheet over the die and high contact pressure between the die and sheet. These harsh tribological conditions result in wear of the die surface due to continuous use over time leading to change in the shape of the die and failures such as cracking of the die and premature tearing on the sheet, ultimately causing production failure. In this research, a finite element analysis is performed to estimate the wear on a square-shaped die in deep drawing. Die is modeled as elastic material while blank shows anisotropic elasto-plastic behavior. Contact elements were used to model the interaction between different parts in this process. Sliding distance of the sheet on the die and also contact pressure on the die are obtained from the FEM model to estimate the abrasive wear on the die. Literature review on the topic suggests that significant efforts have been made to study the wear on the circular die geometry in contrast to the square die geometry. The results of the study may lead to comparison of wear between the circular and square dies. Two different sheet anisotropy are considered: normal anisotropy and planar anisotropy. Variation of wear on the die arc segment in radial and circumferential directions were studied.