Investigation of process parameters of the hydrodynamic deep drawing assisted by radial pressure using Taguchi and finite element methods

Achieving the minimum thinning and required forming force is one of the main purposes in the manufacturing of sheet products using the hydroforming process. This paper investigates forming of the copper sheet using the hydrodynamic deep drawing assisted by radial pressure via the design of experiment method and finite element (FE) analysis. Firstly, the necessary experiments have been designed using the Taguchi design of experiment method. In this design, maximum fluid pressure, punch velocity, the friction coefficient between punch and sheet, the friction coefficient between die and sheet, the gap between blankholder and die, punch nose radius, die entrance radius, and prebulge pressure were considered as input variables and thinning ratio and punch force considered as response functions. Then, designed experiments were performed using an experimental verified FE model and the desired results were obtained. Finally, the optimum levels of input variables were obtained using the Taguchi optimization method and the confirmation experiments were performed using the FE simulation. Results show that the punch nose radius and die entrance radius are the essential parameters on the thinning ratio. Also, the maximum fluid pressure is the most effective parameter on the punch force.