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1

Fluid Pressure Analysis and Process Stability in Sheet Hydroforming with Die For Steel Sheets

Jaber Adil Sh., Mohammed Adnan I., Younis Karem M.

Management Systems in Production Engineering

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2025

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nr 1 (33)

54--59

EN

To increase the process stability and improve the product quality in the sheet hydroforming with die process, it is crucial for identifying and analyzing the dependence of forming pressure on process parameters. The effects of process parameters (blank holder force, frictional condition) on the forming fluid pressure were thoroughly studied experimentally. The main objective is to establish a relationship between the forming fluid pressure and several factors such as blank holder force and friction between die and sheet. The results demonstrate that the maximum fluid pressure increases with increasing blank holder force and friction. Finally, this relationship aims to support calculations and design data and provide control during the SHF-D process.

2

Prediction of the sheet thickness effect on the formability of brass CuZn37 in single point incremental forming using Hooputra ductile damage model

Qate’a Marwa K., Mohammed Adnan I., Jweg Muhsin J.

Advances in Science and Technology. Research Journal

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2025

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Vol. 19, no. 1

95--110

EN

Single point incremental Forming (SPIF) is a novel and practical approach for quickly prototyping and producing small batch sheet metal components. Predicting the impact of sheet thickness in the SPIF process is vital for assessing forming limits, understanding material behavior, optimizing tool design and path, and improving material utilization. It enables engineers to make informed decisions and optimize the process for enhanced formability and part quality. In this work, the numerical simulation of formability of the hyperbolic truncated pyramid with varying wall angles from 20° to 80° by the implementation of the “Hooputra Ductile Damage (HDD) model” in Abaqus/Explicit with the version of (CAE, 2017) has been conducted for brass of CuZn37 to study and predict the impact of the material's sheet thickness on its formability in SPIF process. In addition to that, the effect of sheet thickness on three other output responses: Von Mises stress, equivalent plastic strain, and contact pressure, have been examined. The results demonstrated the excellent success of the Hooputra Ductile Damage model in simulating the formability and capturing the fracture in the SPIF process with a total error ratio of approximately 1.91%. The results also showed that increasing sheet thickness from 0.4 – 1.4 mm increases formability, Von Mises stress, and contact pressure while leading to decreases and then increases the equivalent plastic strain.

3

Characterizing the formability of mild steel in the production of square components by deep drawing process

Mohammed Adnan I.

Advances in Science and Technology. Research Journal

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2025

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Vol. 19, no. 4

117--125

EN

The deep drawing process for square cups is commonly utilized in sheet metal forming, however, there are many associated defects, including fracture, earing, wrinkling. A problem that has more attention in this work is the studying of the influence of the different parameters such as blank diameter, drawing speed, and punch profile radius on the formability of the squared cups. Three circular blanks with diameter (80, 90, 100) mm, three punch profile radius of (4, 7, 10) mm, and three drawing speed of (100, 200, 300) mm/min have been chosen, while the other parameters kept constant. The formability indicators utilized in this study are thickness distribution, maximum thinning and maximum drawing force. The experiments were designed by L9 Taguchi method and analyzed by ANOVA and S/N ratios techniques. The results shown that square cup corners experience higher deformation than that of the side walls cup. Consequently, during plastic deformation, the metal flows along the side walls of the cup are easier and more uniform compared to those in the corners. The best results were obtained from the 80mm blank dimeter, with 100mm/min drawing speed and 7mm punch profile radius according to the uniform thickness distribution, maximum thinning and maximum drawing force.