AÇILI DERİN ÇEKME KALIPLARINDA DİKDÖRTGEN ŞEKİLLİ KAPLARIN DERİN ÇEKİLEBİLİRLİĞİNİN ARAŞTIRILMASI

Derin çekme, sac malzemelerin çekme kalıpları yardımıyla press kuvvetleri altında istenilen yükseklik ve şekillerde üç boyutlu kapların üretilmesi işlemidir. Bu çalışmada, dikdörtgen geometriye sahip kapların açılı derin çekme kalıplarında deneysel olarak ve sonlu elemanlar metodu (SEM) ile sayısal olarak şekillendirilmesi araştırılmıştır. Bunun için matris boşluğuna doğru sacın akmasının rahat olması amacıyla Kalıp/pot çemberi yüzeylerine α=0°, α=3°, α=6°, α=9°, α=12° ve α=15° açılar verilmiştir. Istampa ve matris köşe radyüsleri 8 mm sabit olarak alınmıştır. Deney malzemesi olarak 0,9 mm kalınlığında St37 çelik sac kullanılmıştır. Deneyler, 2500 N, 5000 N, 7500 N ve 10000 N pot çemberi kuvvetleri uygulanarak yapılmıştır. Açıların ve pot çemberi kuvvetinin limit çekme oranı, cidar kalınlığı ve kap hasarlarına yaptıkları etkileri deneysel ve sayısal olarak incelenmiş ve optimum ıstampa kuvveti belirlenmiştir. Elde edilen deneysel sonuçlar, ANSYS sonuçlarıyla karşılaştırılmıştır. Sonuç olarak, farklı açılara sahip dikdörtgen geometriye sahip çekme kalıplarında matris/pot çemberi yüzey açılarının artmasının klasik kalıplara göre çok iyi limit çekme oranı elde edildiği belirlenmiştir. Deneysel olarak elde edilen sonuçlar ile sayısal sonuçların yaklaşık değerler olduğu gözlenmiştir.

INVESTIGATION OF DEEP DRAWABILITY OF RECTANGULAR SHAPED CUPS IN DEEP DRAWING DIES

Deep drawing is the process of obtaining three-dimensional containers of certain depths and shapes under pressing forces with the help of drawing molds of sheet materials. In this study, the numerical shaping of rectangular cups in angled deep drawing dies was investigated experimentally and by using the finite element method (FEM). For this purpose, die/blank holder surfaces have α=0°, α=3°, α=6°, α=9°, α=12° and α=15° angles in order to facilitate material flow into the die cavity. The punch and die corner radii are taken as 8 mm. St37 steel sheet with a thickness of 0,9 mm was used as the test material. The experiments were carried out by applying die/blank holder forces of 2500 N, 5000 N, 7500 N and 10000 N. The effects of angles and die/blank holder force on limit drawing ratio, wall thickness and the damage of cups were investigated experimentally and numerically, and optimum punch force was determined. Obtained experimental results were compared with ANSYS results. As a result, it has been determined that the increase in die/blank holder surface angles in drawing dies with rectangular geometry with different angles provides a higher limit drawing rate than conventional dies. It has been seen that the experimental results and numerical results are approximate values.

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