Numerical and Experimental Analyses of the Deep Drawing Camera Cover

Abstract

The camera cover is a complex 3D-part with many corners and is difficult to form in deep drawing process. One of the most common defects is the tearing that occurs at corners due to the tensile stress concentration. The suitable determination of die and punch parameters leads to reduce the defects and improve the quality of drawn part. Both numerical and experimental analysis can be useful to analyze the deep drawing process for determining the optimal values of tool parameters. In this paper, the formability of camera cover in deep drawing process was considered relating to the geometrical parameters of the die edge radius (RD), the pocket radius on bottom of die (RD1) and the punch nose radius (RP). The results showed that the thickening occurred in the flange area, the stretching occurred in the side wall and the tearing could be occurred in the corners above the punch nose that related to stress concentration if the tool parameters were not optimized. Also, the numerical and experimental results were a good agreement. Both numerical and experimental results cleared that the quality of camera cover relating the thickness was improved when the die geometric parameters were determined suitably with values of RD = 8 mm, RD1 = 4 mm and RP = 2 mm.