Advanced Materials Research Vols.

383-390 (2012) pp 2785-2789 Online: 2011-11-22

© (2012) Trans Tech Publications, Switzerland
doi:10.4028/www.scientific.net/AMR.383-390.2785

Effect of Blank Holder Force with Low Frequency Vibration Technique in

Circular-Cup Deep-Drawing Using AZ31 Magnesium Alloy Sheet

Naoki Horiike1, a, Shoichiro Yoshihara1, b,

Yoshitaka Tsuji1, c and Yusuke Okude1, d
1
University of Yamanashi, 4-3-11, Takeda, Kofu, Yamanashi, Japan
a b c
g11mm029@yamanashi.ac.jp, yoshihara@yamanashi.ac.jp, g09mm023@yamanashi.ac.jp
d
g10df004@yamanashi.ac.jp

Keywords: Sheet forming, Deep-drawing, Low frequency vibration, Blank holder force.

Abstract. In the deep-drawing process, the application of low-frequency vibration to the blank
material has recently been focused on with the aim of improving the friction performance between the
die and the blank material. A servo-controlled press machine is suitable for applying low-frequency
vibration to the blank during the deep-drawing process, because the punch speed and blank holder
force (BHF) are easily controlled as process parameters by using the servo motors. In this study, a
BHF with low-frequency vibration was proposed as a technique for improving deep-drawability,
which is mainly affected by the friction performance and the lubricant condition. We found that the
friction performance between the blank surface and the blank holder was decreased in the case of a
BHF with low-frequency vibration since the lubricating oil rapidly flowed into the clearance during
the forming process. Furthermore, for a BHF with low-frequency vibration, the punch force and the
deformation resistance were lower than those in a deep-drawing test without low-frequency vibration.

Introduction
Magnesium alloys have attracted attention as promising materials for various applications owing to
their light weight and high specific strength. However, they have poor formability at room
temperature because the crystal structure is hexagonal close-packed, in which there are few slip
planes in the case of a pyramidal or cylindrical surface. It has been confirmed that the number of slip
planes in magnesium alloys increases at elevated temperatures, resulting in improved formability [1].
In recent years, various studies on reducing the friction coefficient between the workpiece and the
die in the deep-drawing process have been carried out to improve the formability of magnesium alloys.
It was found that the punch load decreased with decreasing a reduction in the punch load led to a
deterioration in the friction performance between the workpiece and the die. A diamond-coated die
was applied to the deep-drawing process using AZ31 magnesium alloy by Tsuda to reduce the friction
between the die and the blank material. The diamond-coated die improved the formability of
magnesium alloy sheets compared with that obtained using lubricants [2]. Tsuji et al. evaluated the
formability of diamond-like carbon (DLC)-coated blanks. It was concluded that the use of
DLC-coated blanks improved the formability of magnesium alloys in comparison with conventional
lubrication techniques [3]. Siegert applied the pulsating blank holder force (BHF) technique to the
deep-drawing process using a closed-loop system of PID feedback control [4]. As a result, the friction
force between the blank material and the blank holder was decreased as the amplitude of the pulsating
BHF was increased [5]. Manabe investigated and developed a BHF fuzzy control system for the
deep-drawing process.
Deep-drawability by fuzzy BHF control was subsequently improved [6]. A new forming
technology involving a servo press was developed by Tamai, who indicated that the mechanism
underlying the high strength of steel improved the formability [7]. In a previous study, the efficacy of
low-frequency vibration using a high-strength steel sheet was confirmed. However, the effect of a
BHF with low-frequency vibration on the formability of a magnesium alloy sheet at an elevated
temperature has not been clarified.

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2786 Manufacturing Science and Technology, ICMST2011

The aim of this study was to clarify the effect of a BHF with low-frequency vibration on the friction
performance in deep drawing using a magnesium alloy sheet. We expected improved
deep-drawability due to the inflow of lubricant oil into the clearance between the die and the blank
during the process. The effect of a BHF with low-frequency vibration was investigated in circular-cup
deep drawing using an AZ31 magnesium alloy sheet.

Experimental conditions
1. Blank material and lubrication conditions
AZ31 magnesium alloy sheets of 0.5[mm] thickness were used in the experiment. The blank
diameter (D0) of the sheets was 20[mm]. GM100 (Nihon Kohsakuyu CO., kinetic viscosity
o
ν=38.38[mm2/s] at 40[ C]) was used as the lubrication oil applied to the die-side surface of the blank.

2. Circular-cup deep-drawing tests

Fig. 1 shows a photograph of the experimental apparatus and Fig. 2 shows a schematic of the tools
used for the deep-drawing test. A compact press machine with the capability of providing a punch
thrust load of 5.0[kN] was used in the experiment. The blank holder of the press machine is loaded by
the on-line servo motor to ensure flexible loading, the BHF is controlled by the motion controller, and
the punch is controlled by the electrical cylinder. Table 1 shows the experimental conditions in the
deep-drawing test. The punch shoulder radius was 1.5[mm] and the die shoulder radius 2.5[mm]. The
o
deep-drawing test was carried out at 200[ C].

Fig. 2 Schematic of tools used for deep-drawing

Table 1 Experimental conditions in deep-drawing test
o
Temperature [ C] 200
Punch speed [mm/s] 0.5
Drawing ratio (DR=D0/Dp) 2.0
Diameter: Dp [mm] 10.0
Punch
Shoulder radius: Rp [mm] 1.5
Fig. 1 Photograph of Hole diameter: Dd [mm] 11.6
Die
experimental apparatus Shoulder radius: Rd [mm] 2.5

Low-frequency vibration technique

Low-frequency vibration is applied to a BHF to improve the friction performance between the blank
holder and the blank. Fig. 3 shows a schematic of the BHF-time curve. BHF with low-frequency
vibration can be expressed as
BHF = A sin( 2πtf ) . (1)
where A [kN] is the amplitude, t [sec] is time and f [Hz] is the frequency.
A low-frequency of 1.0[Hz]-3.0[Hz] was used. Two BHF conditions, a constant BHF and a BHF
with low-frequency vibration, were adopted in the deep-drawing test. Table 2 shows the experimental
conditions of the low-frequency vibration.
 Advanced Materials Research Vols. 383-390 2787

To apply the low-frequency vibration to the BHF, the blank holder is controlled arbitrarily by the
servo motor. Fig. 4 shows a schematic of the deep-drawing system. The blank holder is moved by
rotary motion using the ball screw, the servo motor, and the coupling as shown in Fig. 4. The BHF and
the punch of the deep-drawing equipment are controlled by analog-digital (A/D) and digital-analog
(D/A) converters, the motion controller, and a PC.

Fig. 3 Schematic of BHF-time curve

Table 2 Experimental conditions of

low-frequency vibration
Frequency [Hz] 1.0, 2.0, 3.0
Amplitude [kN] 0.05, 0.10, Fig. 4 Schematic of deep-drawing system
0.15
Constant BHF 0.3

Experimental results and discussion

1. Circular-cup deep-drawing test
Fig. 5 shows punch load-punch stroke curves and photographs of the drawn cup for comparison
between a constant BHF (0.3[kN]) and a BHF with low-frequency vibration (initial BHF 0.3[kN],
amplitude 0.15[kN], and frequency 3.0[Hz]). Under both BHF conditions, the drawn cups were
deformed without fracture at the punch shoulder. However, the maximum punch load for the BHF
with low-frequency vibration was lower than that for the constant BHF. The reduction of the punch
load is assumed to be due to the effect of the vibration on the flow of lubricant into the micro-pool.
Fig. 6 shows the punch load-punch stroke curves at frequencies of 1.0 and 3.0[Hz] and the same
amplitude of 0.15[kN], and Fig. 7 shows the punch load-punch stroke curves at amplitudes of 0.05
and 0.15[kN] and a frequency of 3.0[Hz]. Effects of the frequency and amplitude on the formability
were confirmed. Under the above conditions, the frequency has little impact on the formability; in
comparison with at the frequency of 1.0[Hz], the maximum punch load was slightly lower at the
frequency of 3.0[Hz]. Furthermore, the punch load was lower at the high amplitude of 0.15[kN].
2. Evaluation of wall thickness strain distribution
Fig. 8 shows the distribution of the wall thickness strain from the bottom to the edge of the same
drawn cup on the RD cross section for the cases shown in Fig. 5. At the punch shoulder of the drawn
cup, the wall thickness of the BHF with vibration is greater than that for a constant BHF. This
indicates that it is possible to control the wall thickness by applying a low-frequency vibration to the
blank holder at the punch shoulder, where blanks are easily broken during the process.
3. Mechanism of friction decrease
Effect of vibration on lubricant in the micro-pool
Fig. 9 shows the mechanism underlying the decrease in friction in the case of a BHF with
low-frequency vibration. When the BHF during the vibration of the blank holder is low at Step
, the
lubrication oil easily flows into the micro-pool on the blank because the clearance between the blank
holder and the die is greater than the thickness of the blank. On the other hand, when the BHF is high
2788 Manufacturing Science and Technology, ICMST2011

at Step , the increase in the actual contact area is suppressed since the hydrostatic pressure is applied
to the lubrication oil in the micro-pool. Therefore, the lubrication performance is maintained by a
BHF with low-frequency vibration during the process. In addition, in the case of a high BHF at Step
, the wrinkling of the blank at the flange part is also suppressed as shown in Fig. 9.

Fig. 5 Punch load-punch stroke curves Fig. 6 Punch load-punch stroke curves

Fig. 7 Punch load-punch stroke curves Fig. 8 Distribution of wall thickness strain

Fig. 9 Mechanism of the friction decrease in the case of BHF with low-frequency vibration
 Advanced Materials Research Vols. 383-390 2789

Surface roughness distribution

Fig. 10 shows the surface roughness of the blank sheet and Fig. 11 shows the drawn cup on the TD
obtained using a BHF with low-frequency vibration (frequency 3.0[Hz] and amplitude 0.15[kN]).
The surface roughness of the blank sheet was 2.003[µmRz] and that of the drawn cup was
1.158 [µmRz]. The lubrication performance is good because the micro-pool of the drawn-cup was
refined.

Conclusion
The punch load in the case of a BHF with low-frequency vibration was lower than that for a constant
BHF in a circular-cup deep-drawing test using AZ31 magnesium alloy. The effect of the frequency on
the maximum punch load was small, although the punch load decreased with increasing amplitude.
Furthermore, in the evaluation of the wall thickness distribution of the drawn cup of the blank, we
confirmed a significant difference in the distributions of wall thickness under different BHF
conditions.

Fig. 10 Surface roughness curve Fig. 11 Surface roughness curve

on blank sheet on wall of drawn cup

References
[1] H. Takuda, D. Inoue: Journal of the JSTP Vol. 43-503 (2002), pp. 1173-1177. (in Japanese)
[2] S. Tsuda: Journal of the JSTP Vol. 51-599 (2010), pp. 1192-1193. (in Japanese)
[3] Y. Tsuji, S. Yoshihara, S. Tsuda, Y. Iriyama, Y. Nakano: Proceedings of the ASME 2009
International Mechanical Engineering Congress & Exposition, IMECE2009-10947 (2009).
[4] K. Siegert, M. Ziegler: Journal of Materials Process technology, Vol. 71 (1997), pp. 126-133.
[5] S. Ali, S. Hinduja, J. Atkinson, P. Bolt, R. Werkhoven: International Journal of Machine Tools
and Manufacture, Vol. 48 (2008), pp. 558-564.
[6] K. Manabe, H. Koyama, S. Yoshihara, T. Yagami: Journal of Materials Process Technology, Vol.
125-126 (2002), pp. 440-445.
[7] Y. Tamai, Y. Yamasaki, A. Yoshitake, T. Imura, T. Kyuno: Journal of the JSTP Vol. 50 (2009),
pp. 1081-1085.
Manufacturing Science and Technology, ICMST2011
10.4028/www.scientific.net/AMR.383-390

Effect of Blank Holder Force with Low Frequency Vibration Technique in Circular-Cup Deep-
Drawing Using AZ31 Magnesium Alloy Sheet
10.4028/www.scientific.net/AMR.383-390.2785

DOI References
[4] K. Siegert, M. Ziegler: Journal of Materials Process technology, Vol. 71 (1997), pp.126-133.
http://dx.doi.org/10.1016/S0924-0136(97)00158-1
[5] S. Ali, S. Hinduja, J. Atkinson, P. Bolt, R. Werkhoven: International Journal of Machine Tools and
Manufacture, Vol. 48 (2008), pp.558-564.
http://dx.doi.org/10.1016/j.ijmachtools.2007.06.013