This paper presents a failure analysis of cylindrical cup drawing dies machined from a polymer composite rapid tooling material. Cup drawing is a complicated process, involving both bending and stretching. In this study, possible die failure modes are identified experimentally. Finite element analyses (FEA) are performed to obtain the stress–strain responses, which are used to determine the dominant failure mode. As cup drawing involves interactions among process parameters, the statistical design of experiments is employed to perform a parametric study. The resulting die failure mode estimation method is verified through experiments.

Issue Section:
Technical Papers
Keywords:
dies (machine tools), drawing (mechanical), failure analysis, mechanical engineering computing, finite element analysis, estimation theory, design of experiments, bending, rapid prototyping (industrial)
Topics:
Corners (Structural elements), Deformation, Design, Failure, Failure analysis, Finite element analysis, Finite element model, Fracture (Materials), Fracture (Process), Stress, Wear, Experimental design, Tooling, Sheet metal, Blanks, Clearances (Engineering), Sheet metal work
1.
Aronson
,
R. B.
,
1998
, “
Toolmaking through Rapid Prototyping
,”
Manuf. Eng.
,
11
, pp.
52
–
56
.
2.
Miller
,
W.
,
1999
, “
Production Dies for Rapid Prototyping of Metal Formed Parts
,”
Fabricator
29
(
4
), pp.
44
–
47
.
3.
Du
,
Z. H.
,
Chua
,
C. K.
,
Chua
,
Y. S.
,
Loh-Lee
,
K. G.
, and
Lim
,
S. T.
,
2002
, “
Rapid Sheet Metal Manufacturing. Part 1: Indirect Rapid Tooling
,”
Int. J. Adv. Manuf. Technol.
,
19
, pp.
411
–
417
.
4.
Cheah
,
C. M.
,
Chua
,
C. K.
,
Lee
,
C. W.
,
Lim
,
S. T.
,
Eu
,
K. H.
, and
Lin
,
L. T.
,
2002
, “
Rapid Sheet Metal Manufacturing. Part II: Direct Rapid Tooling
,”
Int. J. Adv. Manuf. Technol.
,
19
, pp.
510
–
515
.
5.
Park, Y., 2003, “Sheet Metal Forming Using Rapid Prototyped Tooling,” Ph.D. thesis, Georgia Institute of Technology.
6.
Jensen
,
M. R.
,
Damborg
,
F. F.
,
Nielsen
,
K. B.
, and
Danckert
,
J.
,
1998
, “
Applying the Finite Element Method for Determination of Tool Wear in Conventional Deep Drawing
,”
J. Mater. Process. Technol.
,
83
, pp.
98
–
105
.
7.
Jensen
,
M. R.
,
Damborg
,
F. F.
,
Nielsen
,
K. B.
, and
Danckert
,
J.
,
1998
, “
Optimization of the Draw Die Design in Conventional Deep Drawing in Order to Minimize Tool Wear
,”
J. Mater. Process. Technol.
,
83
, pp.
106
–
114
.
8.
Christiansen
,
S.
, and
de Chiffre
,
L.
,
1997
, “
Topographic Characterization of Progressive Wear on Deep Drawing Dies
,”
STLE Tribol. Trans.
,
40
(
2
), pp.
346
–
352
.
9.
Siegert, K., and Haller, B., 1998, “Prototype Draw Dies for Sheet Metal Parts,” Developments in Sheet Metal Stamping, Warrendale, PA, SAE SP-1322, pp. 41–51.
10.
Sachs, G., 1966, Principles and Methods of Sheet Metal Fabricating, 2nd ed., Reinhold Publishing Corporation, New York.
11.
Kalpakjian, S., 1997, Manufacturing Processes for Engineering Materials, 3rd ed., Addison-Wesley, Menlo Park, CA.
12.
American Society of Tool and Manufacturing Engineers, 1965, Die Design Handbook, 2nd ed., McGraw-Hill, New York, NY.
13.
Metals Handbook, Desktop Edition, edited by H. E. Boyer and T. L. Gall, American Society for Metals, 1985.
14.
Kocanda
,
A. Z.
, and
Raddad
,
B.
,
1992
, “
Elasto-Plastic Deformation Behavior and Fracture of Ring-Shaped Dies
,”
J. Mater. Process. Technol.
,
34
, pp.
181
–
186
.
15.
Fatigue and Tribological Properties of Plastics and Elastomers, Plastics Design Library, Norwick, NY, 1995.
16.
Tadmor, Z., and Gogos, C. G., 1979, Principles of Polymer Processing, John Wiley and Sons, New York, NY.
17.
Neter, J., Kutner, M. H., Nachtsheim, C. J., and Wasserman, W., 1996, Applied Linear Statistical Models, 4th ed., McGraw-Hill, New York, NY.
Copyright © 2005
 by ASME
You do not currently have access to this content.