Multistage Deep Drawing with Ironing of Al-killed AISI 1040 Graded Medium Carbon Steel: a Parametric Study

Analysis of multistage deep drawing with ironing was made while manufacturing of cups from 12 mm thick, 60 mm diameter circular blanks of Al-killed AISI 1040 graded medium carbon steel. Quality requirements of the steel in heat treated condition were examined in terms of tensile properties, formability characteristics, and formability limit diagram. Drawability and ironability parameters in multistage cup drawing processes were evaluated in terms of draw ratio; draw reduction; ironing ratio; ironing reduction and thus its press formability in an actual state of practice was shown. Further, were analysed the influences of process parameters such as: semi die angle; interfacial friction coefficient; die-punch clearance on draw and ironing punch forces in each draw stage. The spring back tendency of cups in terms of their trends and degrees with respect to cup heights and draw stages were experimentally determined by conducting split ring test. Thus, a data bank was created as potential references for process engineers to improve the manufacturing process and draw tools as well, particularly for the selected steel.