Optimization of Inconel Die-In EDD Steel Deep Drawing with Influence of Punch Coating Using RSM

In the present industrial applications, conventional methods of metal forming and deep-drawn components of various metals and alloys are uneconomical, and the degree of accuracy, as well as responses, is not reported up to the mark. As far as the modern development and challenges are concerned, the present research has aimed to perform the efficient deep-drawing process for the difficult-to-draw materials by applying different coatings on punch materials. The appropriate Inconel 600 material is selected for the die and punches to perform deep drawing on extra deep-drawn (EDD) steel blank. Deep-drawing process performance is reported quite better using tetrahedral amorphous carbon coating on Inconel punch. In the present research, the selected coating exhibits the best choice among coating of molybdenum disulfide and brycoat titanium nitride. Clearance, blank thickness, and blank holding force are selected as critical input parameters to get the desired deep-drawing responses as limiting draw ratio (LDR), surface roughness, residual stress, and thinning. During the tetrahedral amorphous carbon coating on the punch, responses LDR, surface roughness, residual stress, and thinning are optimized as 1.8586, 0.8934, 268.1440, and 2.7201 by selecting the clearance as 2.7899, blank thickness 4.40, and blank holding force 11.00 using response surface methodology (RSM).