Process Parameters on the Mean Residual Stress of Aluminum Alloy 3004-H19 Cups in the Deep Drawing Process

Residual stress causes visible distortion and reduces corrosion resistance of desired cups. It is the aim of every manufacturing industry to attain quality and maximize profit, thus the cost associated with heat treatment and other residual stress relieving processes should be minimized. The 3004 aluminum alloy is widely used in the container, packaging and automobile industry. This paper presents a 3D explicit deep drawing finite element analysis (FEA) executed with explicit dynamics module in ANSYSR15 workbench. The effect of die-shoulder radius, punch-nose radius, radial clearance, lubrication and punch velocity on the mean residual stress was investigated. A blank of 100mm diameter and 3mm thickness was used in the model. The mean residual stress was determined from the geometric mean of the maximum von-mises and maximum principal stress results for better accuracy. The results showed increasing the die-shoulder radius up to five-time sheet thickness, increasing the punch-nose radius up to four times sheet thickness, setting the punch velocity to 1mm/s, additional radial clearance/sheet thickness between 15-20% and effective lubrication between the tools and blank helps minimize residual stresses