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    Increasing metal utilization by improved drawbead design in deep drawing operations
    (Türk-Alman Üniversitesi, 2013) Mutlu, Beyhan; Tekkaya, A. Erman; Şanal, Ziya
    The deep drawing process is a commonly used forming process in several branches of industry such as the automotive industry, aircraft industry and the household appliances industry. Deep drawing tools are used to produce very large numbers of identical parts. Therefore, even small inefficiencies in metal utilization per part can cause very large amounts of wasted material over a deep drawing tool's life. Drawbeads are commonly used in deep drawing processes to control the flow of the sheet metal into the die cavity. Use of drawbeads increases the amount of scrap metal in deep drawing operations. The primary motivation behind this thesis is to decrease the amount of scrap metal which is produced by the use of drawbeads, and therefore increase the metal utilization in deep drawing processes. In this thesis, two different improved drawbeads are designed to increase the metal utilization in deep drawing operations. This study focuses on the drawbead restraining force generated from the improved drawbeads. 2D and 3D simulations were carried out for the analyses. In the simulations, commercial software programs ABAQUS/Standard and AutoForm were used. An experimental setup was built for the verification of the simulations and the results obtained by numerical simulations are compared with experimental results. DC04 and DP600 steels were used for the simulations and experiments. Comparison of the experimental and simulation results showed good agreement. The results of the simulations and the experiments indicate that, for the selected operations, the conventional drawbead can be replaced by the improved drawbeads, and therefore metal utilization of the process can be increased.