A study on a deep-drawing process with two shaping states for a fuel-filter cup using combined simulation and experiment

In this article, a deep-drawing process using a double-action hydraulic press is examined for its ability to machine the shaping deformation of a fuel-filter cup made from SPCC steel. Many researchers have studied the geometric, physical, and technological parameters of the deep-drawing process. However, most of those studies ignored the optimization parameters of the two shaping deformation states to ensure uniformity of thickness and the disappearance of wrinkling and tearing during machining. In this study, geometric and technological parameters (e.g. blank-holder force, die-shoulder radius, and radial clearance between punch and die) are optimized in both states. The deep-drawing process for a fuel-filter cup is simulated using ABAQUS software, and optimal parameters are determined by applying the Taguchi orthogonal array computation and combining it with an analysis of variance method. The numerical results are then verified with corresponding experiments. The obtained numerical and experimental results show that the die-shoulder radius is one of the most influential parameters affecting the shaping of the cup during the deep-drawing process. Moreover, the influences of technological parameters on the formability of sheet metal are finally analyzed and selected for designing and improving deep-drawing molds.