Title: Optimization of deep drawing products by adding effect of texture pattern in draw bead design

Abstract

Draw beads play an important role in imposing sufficient strain and deformation on blanks in deep drawing process. Using draw beads improve the quality of drawing in terms of creation of details of die on blank and limiting spring back. On the other hand, utilizing draw beads increases die wear and it is inevitable to use lubricant to control the friction and wear rate. In an effort to relegate lubricant from the drawing process and improve the quality of product by controlling the friction between draw beads and blank, the effect of texturing of machining on draw beads were included in design. Three parameters of height, width and length of draw bead as well as the texture pattern created by different machining strategies were considered as input parameters. Three different texture patterns were introduced and the coefficient of friction related to each one was measured using a friction test method. The values of maximum residual stress, maximum plastic strain, maximum punch force, and wrinkling were chosen as output parameters defining the part quality. For case study, the deep drawing process of an industrial die was simulated using ABAQUS/Explicit software. Thereafter, the results of experimental investigation were used for verification of FE model. The effect of each parameter on the quality of drawn parts was investigated using response surface method (RSM). Then, the optimal values of input parameters were obtained by RSM technique. Additionally, the optimization of response surface was carried out using genetic algorithm (GA) contributing to improvement in the output parameters.