Effect of the blank holder force on drawing of aluminum alloy square cup: Theoretical and experimental investigation

In this study, the influence of AA5754-O material, an aluminum alloy, in forming the blank holder force (BHF) in deep drawing process has been investigated. For this purpose, a new experimental system has been prepared. By means of this system, deep drawing process can be implemented through applying variable forces in computer-controlled manner on the blank holder and sheet plate. The numerical model of forming with deep drawing process has been built up and analyzed via the LS-DYNA software. Cup depths, tearing and wall thickness variations of the experimental and numerical results have been compared. It has been observed that no earing and wrinkling have occurred in BHF's between 1.3 and 8 MPa in square deep drawing process, and that tears have occurred in forces exceeding 18 MPa. It has further been observed that the best forming has occurred at 5 MPa, and that the numerical and experimental model developed is in harmony with one another at a rate of 85%.