Effect of Deep Drawing Process Parameters on the Forming Analysis of an Aluminum Monolithic Nonrotational Component Using AutoForm

ABSTRACT This article examined the relationships between the deep drawing process and formability parameters for producing an aluminum monolithic nonrotational component. The deep drawing process was simulated using AutoForm Forming software. Six deep drawing process parameters—the coefficient of friction, drawing gap, die radius, bead height, blank size, and initial blankholder force—were varied at three levels to investigate nonlinearity. A total of 27 simulations were executed. The formability results from the simulations were analyzed through seven output variables: thickening, compression, insufficient stretching, safe forming, risk of splits, excessive thinning, and splits. Relationships between the input and output parameters were analyzed using main effects and interaction plots constructed in MATLAB. The plots showed that the deep drawing process is a nonlinear and complicated process with a high level of interaction among factors. The least responsive formability parameters were the insufficient stretch and the risk of splits. The coefficient of friction showed the most significant effect on all the formability aspects.