Numerical and experimental investigations of hydro-mechanical deep drawing process of laminated aluminum/steel sheets

Abstract The application of hydro-mechanical deep drawing (HMDD) process on laminated sheets combines advantages of both process and material to improve the forming condition of poor formable light-weight metals such as aluminum alloys. In this research, the HMDD process of anisotropic laminated bimetallic sheets has been analyzed using a 3D finite element simulation with implementing Fortran based code for accurate modeling of non-uniform oil pressure distribution. To verify FE results, experimental works were conducted on the widely used laminated aluminum/steel sheets. Based on the developed FE model, parametric studies were performed to investigate the effect of material parameters such as layers thickness and lay-up arrangement on the forming condition, process window and formability of aluminum sheet as key process parameters. Results demonstrated that suitable process condition to attain a successful forming of bimetallic aluminum/steel sheets can be predicted by developed FE model reasonably. Also, It shown that wider working zone was achievable with decrease in drawing ratio, reduction in thickness of sheet with lower strength layer and also when aluminum sheet is in contact with punch (A/S lay-up). In addition, the higher limiting drawing ratio (LDR) and lower thinning in low formable aluminum sheet would be achievable in A/S lay-up than S/A lay-up.