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Investigation of deformation behaviour of steel, aluminium and copper alloys during hydro-mechanical drawing

Nahak Binayak, Kumar Anil, Yadav Anshul, Winczek Jerzy

Archive of Mechanical Engineering

2022

LXIX, nr 3

455--469

The hydro-mechanical drawing combines conventional deep drawing and sheet hydroforming and is widely used in the automotive industry. In this study, we designed and fabricated an indigenous experimental set-up that is low cost, low weight and portable. This study investigated the deformation of sheet metals into hemispherical cup-shaped parts made of different materials, viz., aluminium 8011 alloys, copper C12200 and steel EN10130 alloys. The initial thickness of sheet metal was 0.4 mm, the most common thickness range used in automotive applications. The deformation behaviour in terms of dome height has been measured by varying the pressure of the fluids. Aluminium 8011 alloy sheets showed a maximum dome height of 11.46 mm at a pressure of 1.47 MPa with no rupture. Steel EN10130 sheets had a maximum dome height of 10.89 mm at a pressure of 9.31 MPa. It was concluded that the behaviours of materials are different in the hydro-mechanical drawing process than in mechanical tests. Copper C12200 sheet showed superior formability with a maximum dome height of 18.91 mm at a pressure of 7.06 MPa than other materials without fracture.