The Numerical Simulation And Optimum Design On Open Kettles Cover

Deep tube is a typical drawing part, and the multi-stage drawing process is used sidely in a variety of industrial fields. In multi-stage deep drawing process, the total drawing process, the total amount of deformation is divided several parts, and formed sequentially in several deep drawing steps. In this process, the blank of later steps'has experience several deformation, the material mechanics and the part's geometry has changed, so multi-stage deep drawing has some difference from first deep drawing, the deformation mechanism is very complicated and the mechanical properties for the final product are difficult to predict, the process design is not easy for the manufacturing of a product of desired shape. The traditional design process of the multi-stage drawing process depends too much empirical formulas and data, and many theories and eaperiences are derived from hypothesis and simplification of first deep drawing process, so the multi-stage drawing has many difficulties, such as high cost, long period, and theory analysis is lagged serely. And the experience knowledge from production has defect which is not obvious and not systemic. Direct dynamic results can be obtained by simulation. The results can guide actual production, reduce waste rate and boost die life. So study on this kind of parts by numerical simulation has both theoretic and practical value.It is a future trend using advanced manufacturing technologies, such as numerical simulation to solve the problems procuced in industry. Based on the numerical simulation and orthogonal experiment, and taking the open kettles cover as an example, a comprehansive research of multi-stage drawing is performed , and opimize the die and drawing process are explored in this paper. The study is to perform plastic finite element method for the whole process of the open kettles cover forming and forecast the question or defect may appears, through using the advanced software DYNAFORM of American ETA, Inc. then the technology and die parameters are optimized, which provide theory basis for forming, equipment and die design of the open kettles cover. Experiment data were processed through least square method and orthogonal design, and the law of multi-stage deep drawing by playing a lot of numerical simulation of different technical parameters and material performance, such as the blank-holder force, puch corner profile, and the friction of die. On this basis, equipment and die are manufactured. The experiment results fit mutually with the simulation data.Finally, the research results indicate that the numerical simulation and orthogonal experiment design can forecast the shortcoming in drawing used suitable test number. Such as wrinkle, split and optimize the die and drawing process. So that the process design and die design experience is raised up to the theoretical guidance and thus greatly improve the design quality and reduce the cost of debugging die, shorten the production cycle, in order to speed up the products updating, develop the productivity and create beneficial conditions.