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<p>The improvements in the sheet metal industry have largely been influenced by the improvements in the formability of the material, modernized tools, computer simulations, and flexibility of the processes. Although these innovations have helped in reducing costs and reducing production cycles, there are also challenges that have to be addressed. In the present study, EDD 513 steel used for manufacturing of automobile oil drain cup having thickness of 1.5&#xa0;mm was investigated through finite element analysis (FEA) and experimental validation for deep drawing operation. Few simulations conducted during intital phase resulted in excessive thinning of approximately 16% along with severe wrinkling at the flange region, leading to rejection of the tooling design. Parametric investigations were performed by varying die entry radius range from (4–11&#xa0;mm), varying friction coefficient, blank holding force and die-punch clearance (0.31&#xa0;mm and 0.82&#xa0;mm). The optimized conditions obtained through FEA simulations demonstrated that an 11&#xa0;mm die entry radius provided acceptable formability and satisfied industry requirements for defect-free production.The thinning percentage was reduced to 14% with low wrinkle formation at body and flange. The experimantal trial shows the inline aggrement with simulations results with devation of 3% in thickness and geometry.The findings underscore the significance of process parameters like friction, die entry radius and punch-die clearance in creating the best formability in the part.</p>

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Enhancing formability in EDD 513 oil drain cup by simulation and experimental investigation

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月6日

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  • Chandrakant V. Bhatia,
  • Dhiren Patel,
  • S. Krishna Prasad,
  • Abdul Amir H. Kadhum,
  • Yohanis Dabesa Jelila,
  • Ahmed Shakir Al-Hiti

摘要

The improvements in the sheet metal industry have largely been influenced by the improvements in the formability of the material, modernized tools, computer simulations, and flexibility of the processes. Although these innovations have helped in reducing costs and reducing production cycles, there are also challenges that have to be addressed. In the present study, EDD 513 steel used for manufacturing of automobile oil drain cup having thickness of 1.5 mm was investigated through finite element analysis (FEA) and experimental validation for deep drawing operation. Few simulations conducted during intital phase resulted in excessive thinning of approximately 16% along with severe wrinkling at the flange region, leading to rejection of the tooling design. Parametric investigations were performed by varying die entry radius range from (4–11 mm), varying friction coefficient, blank holding force and die-punch clearance (0.31 mm and 0.82 mm). The optimized conditions obtained through FEA simulations demonstrated that an 11 mm die entry radius provided acceptable formability and satisfied industry requirements for defect-free production.The thinning percentage was reduced to 14% with low wrinkle formation at body and flange. The experimantal trial shows the inline aggrement with simulations results with devation of 3% in thickness and geometry.The findings underscore the significance of process parameters like friction, die entry radius and punch-die clearance in creating the best formability in the part.