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Procedia Manufacturing 46 (2020) 623–629

13th International Conference Interdisciplinarity in Engineering (INTER-ENG 2019)

13th International Conference Interdisciplinarity in Engineering (INTER-ENG 2019)
Evaluation of the Effect of Contact and Friction on Deep Drawing
Evaluation ofAnalysis
Formability the Effectfor
ofLightweight
Contact andAluminum
Friction onLithium
Deep Drawing
Alloy
Formability AnalysisUsing
for Lightweight
CylindricalAluminum
Cup Lithium Alloy
a,b, Using Cylindricala,c Cup a b
Kenza Bouchaâla *, Mohamad Fathi Ghanameh , Mustapha Faqir , Mohamad Mada ,
Elhachmi a,c b
Essadiqi
Kenza Bouchaâlaa,b,*, Mohamad Fathi Ghanameh , Mustapha Faqira, Mohamad Madab,
b
a
Elhachmi
International University of Rabat, AERO school of Essadiqi
engineering, LERMA lab. Rocade Rabat-Salé, 11 100 Sala el Jadida, Morocco
b
Mohammed V University, Mohammadia School of Engineers, ITACS lab. Rabat, Morocco
ac
International University
Department of of Rabat,
mechanical AERO schoolofofmechanical
conception-faculty engineering,
andLERMA lab.engineering-Damascus
electrical Rocade Rabat-Salé, 11University,
100 Sala elDamascus,Syria.
Jadida, Morocco
b
Mohammed V University, Mohammadia School of Engineers, ITACS lab. Rabat, Morocco
c
Department of mechanical conception-faculty of mechanical and electrical engineering-Damascus University, Damascus,Syria.

Abstract

Abstract
Deep drawing is one of the most important forming process manufacture, in which a conversion of flat sheet metal formed into
desired shape and size by subjecting the sample to a plastic deformation. The control of physical and geometric parameters is
Deep drawing
mandatory is one of
to reduce the most
defects and important
achieve a forming process
height quality ofmanufacture,
drawn product. in which
Aluminuma conversion of flat
alloys sheet sheet metal
forming formed into
have become key
desired shape and size by subjecting the sample to a plastic deformation. The control of physical and geometric
factor for product cost reduction and a quick technological development in many manufacturing areas like aerospace, automobile parameters is
mandatory to reduce
and electronic defects
industries. and achieve
Friction is one aofheight quality of drawn
the geometrical product.
parameters which Aluminum alloys
effect deep sheet process.
drawing forming have become key
It is important to
factor
controlfor product
friction cost reduction
between tools andand a quick
blank. technological
Therefore, a focusdevelopment in many
on highlighting manufacturing
its influence on theareas like aerospace,
formability automobile
was studied. In this
and electronic industries. Friction is one of the geometrical parameters which effect deep drawing process.
work, friction between work piece and tools was studied, in predicting cylindrical cup deep drawing manufacture of AA2198 Al- It is important to
control
Li alloyfriction between
sheets, in order totools and blank.
investigate Therefore,ofa friction
the influence focus ononhighlighting
the quality of itsthe
influence on the formability was studied. In this
final product.
work,
Finitefriction
elementbetween
analysiswork piece
is used forand
thistools was studied,
research. in predicting
A 3D model cylindrical
was simulated cupthe
using deep drawing manufacture
FE-package of AA2198
ABAQUS software Al-a
with
Li alloy sheets, in order to investigate the influence of friction on the quality of the final product.
combination of Taguchi method. Relying to the results and discussion, it can be concluded the best combination.
Finite element analysis is used for this research. A 3D model was simulated using the FE-package ABAQUS software with a
combination
© 2019 Theof Authors.
Taguchi method. Relying
Published to the results
by Elsevier B.V..and discussion,
This it can access
is an open be concluded
article the best combination.
under the CC BY-NC-ND license
©(http://creativecommons.org/licenses/by-nc-nd/4.0/)
© 2020
2019The Authors.
The Published
Authors. by Elsevier
Published B.V. B.V.. This is an open access article under the CC BY-NC-ND license
Peer-review
This is an openunder
accessresponsibility ofbyCC
article under the
Elsevier
the scientific committee
BY-NC-ND of the 13th International Conference Interdisciplinarity in
license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
(http://creativecommons.org/licenses/by-nc-nd/4.0/)
Engineeringunder responsibility of the scientific committee of the 13th International Conference Interdisciplinarity in Engineering.
Peer-review
Peer-review under responsibility of the scientific committee of the 13th International Conference Interdisciplinarity in
Engineering
Keywords: Abaqus; Aluminum-lithium; Deep Drawing; Finite Element Simulation, Friction,Taguchi.

Keywords: Abaqus; Aluminum-lithium; Deep Drawing; Finite Element Simulation, Friction,Taguchi.

* Corresponding author. Tel.: +212 6 52 80 31 30.

E-mail address: kenza.bouchaala@uir.ac.ma
* Corresponding author. Tel.: +212 6 52 80 31 30.
E-mail address:
2351-9789 kenza.bouchaala@uir.ac.ma
© 2019 The Authors. Published by Elsevier B.V.. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/)
2351-9789
Peer-review©under
2019responsibility
The Authors. of
Published by Elsevier
the scientific B.V..ofThis
committee the is an International
13th open access article under Interdisciplinarity
Conference the CC BY-NC-ND in license
Engineering
(http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review under responsibility of the scientific committee of the 13th International Conference Interdisciplinarity in Engineering

2351-9789 © 2020 The Authors. Published by Elsevier B.V.

This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review under responsibility of the scientific committee of the 13th International Conference Interdisciplinarity in Engineering.
10.1016/j.promfg.2020.03.089
624 Kenza Bouchaâla et al. / Procedia Manufacturing 46 (2020) 623–629
2 Kenza Bouchaâla et al. / Procedia Manufacturing 00 (2019) 000–000

1. Introduction

Aerospace manufacturing industries are very attentive to the fabrication of different sheet metal with good
qualities. The capability of sheet metal to attend high plastic deformation into a final profile without failures is
defined as formability. Deep drawing is one of Various sheet metal forming processes. This technic is based on the
deformation of a sheet blank by the action of a punch Force (Fp) and compressed by the blank holder force (Fh) into
desired profiles as it is illustrated in Fig.1.
Aluminum base alloy having low density used in aerospace industry, However, titanium alloys and composite
materials have been a real competition for Al alloys [1], which led aluminum manufacturers to pay a renewed
attention in a new type of aluminum alloy called Al–Li alloys [2].
Lithium is the lightest metallic element, it’s the only metal when it’s alloyed to aluminum the density decreases
and the elastic modulus improves, the addition of 1% of Li could reduce 3% in density , and nearly raises 6% in
elastic modulus [3,4]. Moreover, adding 2% lithium, the density is decreased by 10%, and the modulus of elasticity
is increased by 25% to 35% [5], furthermore, the aluminum-lithium alloy has high specific strength, specific
stiffness, high modulus of elasticity, instead of the conventional high-strength aluminum alloy, the structural quality
can be reduced by 10% to 20%, and the rigidity is increased by 15% to 20% [6].
Three generations of Al-Li alloys were obtained [7]. The third generation alloys began in the late 1980s and is
ongoing, and is considered to be the main structural material of the 21st century aircraft [8-10].
Several parameters affecting the smooth forming of cylindrical deep drawing parts, such as blank holder force,
die corner radius, Punch corner radius, Yield criteria, Coefficient of friction and so on. K.Bouchaâla et. al
investigated that a good control of blanking force is required to avoid wrinkling in case of law force [11]. Die corner
radius is one of the pertinent parameters which influenced the quality of the formed shape. K. Bouchaâla et al.
analyzed that die shoulder radius is recommended to be about 8 times sheet thickness to minimize earring high and
enhance the quality of the formed shape [12]. The influence of anisotropic in sheet thickness during deep drawing
was predicted implementing Hill’s yield criterion as a material description using ABAQUS software [13].
Friction is one of the geometrical parameters which influence deep drawing process, therefore, many researchers
have focused on highlighting its influence on the formability. Hjijaj et al. [14] studied a friction model by the
friction condition, that was a generalization of non-associated sliding rule was defined using isotropic Coulomb’s
frictional contact law to anisotropic friction conditions. Michałowski et al. [15] analyzed a theoretical approach on
friction limit surfaces and sliding rules. Browne et al. [16] investigated the effects of forming factors, including
lubrication type and lubrication position, on the drawing formability. Bouchaâla et al. [17-18] predicted the
parametric optimization concerniong the AA2090 Al-Li alloy on the friction coefficient.
The optimal design of the deep drawing process parameters is a multi-factor, multi-level problem, so the
experimental design method can be used. Among several DOE methods he orthogonal test design method has many
advantages, such as reduce the number of tests and save manpower, material resources and financial resources. [19]
This paper intends to combine finite element simulation with Taguchi orthogonal test design method in order to
optimize the design parameters of deep drawing.
The purpose of the optimized design is to avoid thinning, so that the deep drawing can be completed smoothly,
and thus the optimization target can be determined the convenient coefficient of friction.

Nomenclature

µd : Coefficient of friction between blank and die .

µh : Coefficient of friction between blank and holder.
µp :Coefficient of friction between blank and punch .
FE: Finite element.
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Kenza Bouchaâla et al. / Procedia Manufacturing 00 (2019) 000–000 3

1.1. Design of numerical deep drawing

In the present paper ABAQUS software was used as finite element software for modelling the deep drawing
process. A two-dimensional model of cylindrical deep drawing is shown on Fig. 1, the regions of different contact
surface occurs with different values.

Fig. 1. 2D Cylindrical Deep drawing design and the regions of different contact surface:
A) between the flange of the blank and the (die and blank holder)
B) between the blank and the die corner radius
C) between the blank and the punch nose radius.

Fig. 2. 3D Finite element Cylindrical deep drawing model

Before deformation (left), After deformation(right).

The die, punch and holder of the three-dimensional finite element cylindrical deep drawing model were modelled
as rigid bodies whose motion was governed by the reference node and were meshed with (R3D4) surface elements,
while the blank was modelled as a deformable body, using reduced integration shell element (S4R) [20] as it is
demonstrated in Fig.2. A three-dimensional quarter section of cylindrical cup was modelled, the mass scaling as
well was used in order to reduce the CPU time and save computer memory, with the corresponding symmetry
boundary conditions.
The dimensions used in the present model are token from literature [21] .The blank had a thickness of 1.6 mm.
626 Kenza Bouchaâla et al. / Procedia Manufacturing 46 (2020) 623–629
4 Kenza Bouchaâla et al. / Procedia Manufacturing 00 (2019) 000–000

, 97.46 mm 101.48mm and 158.76mm are the diameters of punch, die and blank respectively, while 12,7 mm was
the radius concerning the corner of both punch and die. The mechanical properties which characterize the behaviour
of AA2198 Al-Li alloy are given in Table 1 [22].

Table 1. Mechanical properties of AA2198 Al-Li Alloy.

Al-Li Density Young’s Poisson’s Hardening law
(Kg/dm3) modulus ratio υ
Alloys E (GPa)
AA2198 2.8 75 0.33 σ=kεn

1.2. The model’s validation

With the aim of validating the present model a comparison between the present finite element cylindrical deep
drawing model and the experimental published deep drawing test done by Colgan et. al [23] is studied.
The results of the published values with the utilized FEA are shown in Table 2, the values obtained coincide with
the thickness at the nearest node to the corresponding point of Ref [23]. Moreover, the present values are very near
to the published results with differences which do not exceed 2.2% on average for experimental and differences and
0.4% on average for numerical.

Table 2. Comparison of thickness variation at the end of the simulation between present model and published results.
1 2 3 4 5 6 7 8 Average
Experimental
1,132 1,032 0,888 0,83 0,823 0,871 0,966 0,979 0,94013
results [23]
Numerical results
1,11 1,08 1,01 0,955 0,799 0,844 0,942 0,958 0,96225
[23]
Present FE model 1,10 1,05 1,01 0,91 0,881 0,899 0,942 0,940 0,96626

1.3. Parametric optimization

If this study 3 factors and 3 levels problem are used in the orthogonal test design method, the specific level of
parameters used are summarized in Table 3. The values of chosen control parameters were based on the results of
Ref [24] In the process parameter optimization design, the influence of the corner radius of the convex and concave
molds can be temporarily ignored. Only the contact between the blank and different tools is considered as it was
illustrated in Fig. 1.

Table 3. process parameters and levels.

Factor Level-1 Level-2 Level-3

Coefficient of friction between blank and die µd 0,14 0,16 0,18
Coefficient of friction between blank and holder µh 0,14 0,16 0,18
Coefficient of friction between blank and punch µp 0,1 0,15 0,2

2. Results and discussion

According to the test factor and the number of levels, orthogonal test L9 (33) is used to develop orthogonal array
(OA), and only 9 simulations were modeled to obtain the optimality. The assignment of parameters along with the
OA matrix is shown in Table 4.
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Kenza Bouchaâla et al. / Procedia Manufacturing 00 (2019) 000–000 5

Table 4. Taguchi Orthogonal array (L9).

Treat No µd µh µp Thinning (mm)

1 0,14 0,14 0,1 1,50147
2 0,14 0,16 0,15 1,47179
3 0,14 0,18 0,2 1,50824
4 0,16 0,14 0,15 1,50563
5 0,16 0,16 0,2 1,50918
6 0,16 0,18 0,1 1,49361
7 0,18 0,14 0,2 1,50804
8 0,18 0,16 0,1 1,51378
9 0,18 0,18 0,15 1,48811
Since each model corresponds to a different level of each factor, only the levels in each test factor are changed
during the simulation, and other factors than the test factors are kept constant to reduce or avoid the systemic effects
of other factors on the test results.

a) b)

c)

Fig. 3. Variation of Thinning with the variation of control parameters:

a) Coefficient of friction between blank and die b) Coefficient of friction between blank and holder
c) Coefficient of friction between blank and punch.
628 Kenza Bouchaâla et al. / Procedia Manufacturing 46 (2020) 623–629
6 Kenza Bouchaâla et al. / Procedia Manufacturing 00 (2019) 000–000

According to the optimized design scheme, the AA2198 aluminum-lithium alloy deep drawing model under a
series of different process parameters is carried out, and the test results are calculated, analyzed and summarized to
determine the best combination between the three coefficients of frictions.
The aim of the current optimized design is to avoid thinning, so that the deep drawing can be completed
smoothly. From Fig.3 it is detected that the optimum condition to reduce thinning is µd at Level3, µh at Level1, and
µp at Level3.

3. Conclusion

Friction is one of the pertinent parameters which affect the quality of final drawn shape, therefore a
numerical simulation for the prediction of friction effect of AA22198 Al-Li alloy sheet were achieved using
ABAQUS/EXPLICIT software. In this study a combination between finite element analysis and Taguchi
method was used. As a result the best combination of friction coefficients to reduce thinning is 0.18 ,0.14 and
0.20 concerning µd, µh and µp respectively.

Aknowledgement

The authors of this paper acknowledge the financial support by “Centre National pour la Recherche
Scientifique et Technique” (CNRST) Rabat, Morocco.

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