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In this paper a new modified processing route has been proposed for producing long cylindrical cups from 12 mm thick circular blanks of AISI 1020 steel (Aluminium (Al) -killed). In this route, flat blanks were made to preformed shape by stamping operation, followed by multistage deep drawing processes(without blank-holder and with inter-stage stress relief annealing) to increase cup depth. Wall ironing was also purposefully included in each draw step to reduce wall thickness and earing tendency on cup edges. Thus, evolution of wall thickness distribution, Drawability and Ironability, punch force history, and strain distribution profiles on outer cup surfaces were obtained as the effects of interaction between processes, tools and material. The overall draw stages showed: LDR 2.06; overall draw reduction >50% with a drawing efficiency ~72%; LIR 3.55; overall ironing reduction >70% with an ironing efficiency ~68%, which were achieved in the experimental works.

materials research

12 mm Thick Circular Blanks of Al-killed AISI 1020 Steel -Applied for Cylindrical Cup Manufacturing by Multistage Deep Drawing with Simultaneous Ironing