Simulation Study of Effect of Punch Corner Radius and Binder Holding Gap on Formability of AA 6061 Using AFDEX

The objective of this project is to study the effect of punch corner radius, binder holding gap and punch velocity in single stage deep drawing process. Analysis is carried by varying punch velocity, punch corner radius and binder holding gap and keeping BHF, coefficient of friction, initial temperature constant. CAD modelling of dies is done using Solid Edge V19 and simulation of single stage deep drawing is carried out using AFDEX simulation software. The punch velocity is varied from 850mm-s to 950mm-s and punch corner radius is varied in between 2mm to 5mm. The BHF (775N) and co-efficient of friction (0.1) are kept constant. In case of binder holding gap, it is varied in steps of 0.25mm from 0mm to 1mm and binder holding force is doubled (1500N). The forming type is cold and hence the temperature is maintained at 25ºC.The material used for this simulation process is Aluminium Alloy AA6061. Twenty-four simulations were carried in AFDEX simulation software to get damage values using different punch velocities, punch corner radius and binder holding gap. We observed from the results that punch corner radius influence the thickness distribution in deep drawn cup and binder holding gap have influence on wrinkle formation.