Prediction of Earing in Cylindrical Deep Drawing of Aluminum Alloys Using Finite Element Analysis
Deep drawing of sheet metal is one of the most important transformation’s process in which a sheet metal blank is
drawn into a forming die via a punch force. The conventional deep drawing of sheet metal techniques, known for their wide
usage in several industry sectors, are experimental and expensive processes. Numerical simulation using Finite Element
Methods (FEM) offers the ability of analyzing the feasibility of a process, allowing the benefit of saving time and
considerably reducing costs by comparison with traditional methods. This virtual simulation requires the realization of the
tools and their adjustment according to the resulting data till seizing a satisfactory adequacy of results. In this study, a Hill48
anisotropic yield criterion was adopted to express the mechanical material properties using ABAQUS/EXPLICIT software.
A finite element model is developed for the 3D numerical simulation of sheet metal deep drawing process. Two aluminum
alloys AA1050 and AA1100, were studied with the focus on the influencing parameters involving both physical and material
properties that affect the final predicted part. The developed model predicts the thickness and the formation of ears of the
blank based on plastic Hill yield criteria. The earring prediction was simulated using extra deep drawing.
Keywords- Deep Drawing, Finite Element Analysis, Anisotropy, Aluminum Alloys.