An Investigation of the Effects of a Sheet Material Type and Thickness Selection on Formability in the Production of the Engine Oil Pan with the Deep Drawing Method

In internal combustion engines, in a way integrated under the engine block, the oil pan is used to store the engine oil, to separate foreign substances in the oil coming from the engine block, to lubricate the moving parts, to help the engine cooling system. In this study, by using different materials such as DC06 (IF), AISI 304, Al6082, and DC01 and selecting different thicknesses such as 1.5 mm and 2 mm, the deep drawing method was applied to them, and their formability behaviors with deep drawing were investigated. The effects of the sheet material type and thickness parameters on the tensile force and wall thickness variation on a sample engine oil pan formed by deep drawing were determined. Different parameters were determined for the sample engine oil pan. According to the analysis results, it was detected that the wall thicknesses of the sensitive points were determined to decrease by 0.86 mm, 0.62 mm, and 0.37 mm, respectively, for deep drawn samples with a 1.5 mm thickness (AISI 304, DC06, DC01), but tearing occurred in the Al6082 material. On the other hand, when the sheet material thickness was increased to 2 mm, it was observed that the thickness change rates decreased by 13% in DC06, 0.7% in AISI 304, 33% in Al 6082, and 4% in the DC01 material type in comparison with the initial sheet thickness of 1.5 mm. The results of the analysis obtained in this study demonstrated that these four materials had superiorities over each other, that the thickness of the material was an essential criterion in deep drawing, and that the use of a 2 mm thick AISI 304 material among the selected materials in the production of the engine oil pan was more suitable.

Keywords:

formability, engine oil pan, deep drawing, finite element analysis, metal sheet thickness distribution,

PDF

___

Ethiraj, N. and Kumar., V. S. (2010). Experimental investigation on warm deep drawing of stainless steel AISI 304. Applied Mechanics and Materials, 26, 436-442.
Choi, T. H., Choi, S. K., Na, J., Et Al. (2002). Application Of Intelligent Design Support System For Multi-Step Deep Drawing Process, Journal Of Materials Processing Technology, 130, 76-88.
Tasdemir, V. (2013). Finite element analysis of the effect of die geometry on deep drawing process. Kahramanmaraş Sütçü İmam Üniversitesi Mühendislik Bilimleri Dergisi, 16(1), 43-47.
Özek, C. and Özbay, V. (2011). Experimental and Numerical Investigation Of Limit Drawing Ratio for Square Cups of Angle Deep Drawing Die. 6 th. International Advanced Technologies Symposium.
Özdilli, Ö, Erdin M., E. and Erdoğan, M. (2019). Investıgatıon Of Effects Of Varıable Blankholder Force On Deep Drawıng Process Of 6082 Alumınum Alloy. Fresenıus Envıronmental Bulletin 28.4 A, 3324-3332.
Kim, T., Yang, D. Y. and Han, S. (2004). Numerical Modeling Of The Multi-Stage Sheet Pair Hydroforming Process. Journal Of Materials Processing Technology, 151, 48-53.
Yanarocak, R. and Çekiç, A. (2015). CAE model correlation & design optimization of a laminated steel oil pan by means of acceleration and strain measurement on a fired engine. International Journal Of Engineering Technologies, 1, 13-18.
Kumar, S. and Subramanyam, P. (2015). Design and weight optimization of oil pan by fe analysis. International Journal of Research In Advanced Engineering Technologies,4.2, 229-247.
Özdemir, A.O., Şirin, H. and Karataş, Ç. (2017). Investigation of the effect of alloy elements in steel sheets used in the automotive industry. Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım Ve Teknoloji, 5, 109-119.
Rajendraprasad, B. (2015). Design and structural optimization of oil pan. International Journal & Magazine of Engineering, Technology, Management and Research, 2, 671-677.
Chen, D., Xu, Y., Zhang S. Et Al. (2018). Evaluation of numerical and experimental investigations on the hybrid sheet hydroforming process to produce a novel high-capacity engine oil pan. The International Journal Of Advanced Manufacturing Technology, 97, 3625-3636.
Takuda, H., Mori, K., Masuda I. Et Al. (2002). Finite element simulation of warm deep drawing of aluminium alloy sheet when accounting for heat conduction. Journal Of Materials Processing Technology, 120, 1-3, 412-418.
Gauchía, A., Álvarez-Caldas, C., Quesada, A., & San Román, J. L. (2009). Material parameters in a simulation of metal sheet stamping. Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, 223(6), 783-791.
Hwang, S. J., Park, W. G., Kim, C., & Oh, S. W. (2008). Gas dynamics analysis of an air pocket in the metal-stamping process. Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, 222(10), 1755-1768.
Osma, A. (2014). An investigation on the stress–strain relationship of cold-rolled steel sheets used in the automotive industry. Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, 228(5), 565-579.
Lee, K. H., Shin, J. K., Song, S. I., Yoo, Y. M., & Park, G. J. (2003). Automotive door design using structural optimization and design of experiments. Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, 217(10), 855-865.
Colgan, M. and Monaghan, J. (2003). Deep drawing process: Analysis and experiment. Journal Of Materials Processing Technology, 132, 1-3, 35-41.
Cheng, H., Cao, J. Yao H. Et Al. (2004). Wrinkling behavior of laminated steel sheets. Journal Of Materials Processing Technology, 151, 1-3, 133-140.
Kitayama, S., Natsume, S., Yamazaki, K. (2016). Numerical investigation and optimization of pulsating and variable blank holder force for identification of formability window for deep drawing of cylindrical cup. International Journal Of Advanced Manufacturing Technology, 82, 1-4, 583-593.
Candra, S., Batan, I. M. L., Berata W. Et Al. (2015). Analytical study and fem simulation of the maximum varying blank holder force to prevent cracking on cylindrical cup deep drawing. 12th Global Conference On Sustainable Manufacturing - Emerging Potentials, 26, 548-553.
Chengzhi, S., Guanlong, C. and Zhongqin, L. (2005). Determining the optimum variable blank-holder forces using adaptive response surface methodology (ARSM). International Journal Of Advanced Manufacturing Technology, 26, 23-29.
Zheng, K. L., Lee, J. Y. Lin, J. G. Et Al. (2017). A buckling model for flange wrinkling in hot deep drawing aluminium alloys with macro-textured tool surfaces. International Journal Of Machine Tools & Manufacture, 114, 21-34.
Browne, M. T. and Hillery, M. T. (2003). Optimising the variables when deep-drawing cr1 cups. Journal Of Materials Processing Technology,136, 1-3, 64-71.
Erdin, M. E. and Özdilli, Ö. (2019). Deep drawing of polymer coated metal sheets. Journal Of Mechanical Science And Technology, 33, 5383-5392.
Kim, S. H., Kim, S. H. and Huh, H. (2001). Finite element inverse analysis for the design of intermediate dies in multi-stage deep-drawing processes with large aspect ratio. Journal Of Materials Processing Technology, 113, 779-785.
Özdilli, Ö., and Erdin, M.E. (2018). Comparison of common deep drawing steel sheets in terms of blank holder force and friction conditions. International Journal Of Automotive Science And Technology, 2.3, 36-41.

International Journal of Automotive Science and Technology-Cover

Yayın Aralığı: Yılda 4 Sayı
Başlangıç: 2016
Yayıncı: Otomotiv Mühendisleri Derneği

Arşiv