Finite Element Simulation and Experimental Study of Forming Conical Parts, Using Hydrodynamic Deep Drawing with Radial Pressure

Forming conical parts is one of the complex and difficult fields in metal forming processes. Because of low contact area of the sheet with punch in the initial stages of forming, high stresses is applied to the sheet that causes tearing. Moreover, since most of the sheet surface in the area between the punch tip and the blank holder is free, when the sheet is drawn, wrinkles are occurred in the wall of the part. Thus, these parts are normally formed by spinning, explosive forming, or multistage deep drawing processes. A few number of research works have been carried out in the area of forming conical parts. In this paper, forming these parts in the hydroforming process is studied, using finite element simulation and experiments. By examining several pressure paths, the effect of pressure path on tearing and thickness distribution of the sheet has been studied. By obtaining the desired pressure path, a conical part with a high depth has been formed.