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Go to Editorial ManagerIn this research, experimental and analytical deep drawing of the several-stages design mold is produce hexagonal cup and also proved the influence of the thickness of the sheet on the allocation of strain and laminating in curvature of the cup area for all stages of the drawing. Three stages deep drawing mold was designed and constructed to carry out the experimental work required to produce a hexagonal cup of (28.25 mm by 24.5 mm) , (60 mm) high drawn from a circular flat sheet (80 mm diameter), made from low carbon steel (1006–AISI). Analysis program (ANSYS11.0) to perform the finite element method to accomplish the analytical side of the search. Three types of thickness sheet (tt°= 0.5, 0.7,1 mm) with constant radius of curvature of punch equal to (RRpp =4) mm, radius of curvature of die equal to (RRdd=8 mm)and radius of curvature of wall of die (RRcc= 4 mm) were used. From the experimental and analytical results of the three stages of drawing, it has been found that drawing load less than the more advanced stages of drawing operation on the wall of cup, maximum laminating take place at curvature of the cup area with sheet thickness equal to (tt°=0.5 mm) and maximum thickeningtake place at the at throat cup with sheet thickness equal to (tt°=1 mm), the maximum values of strains (radial, hoop, thickness andeffective)take place at throat cup with sheet thickness equal to (tt°=1 mm).
With the development of manufacturing techniques, the demands have increased on tools with flexible components that can produce parts with different shapes and sizes only by replacing the rigid part of these tools, since the flexible part can match the required geometry. This study is focused on effects of rubber hardness and sheet thickness on the springback developed on the produced parts. Silicone rubber with three hardness (40,60 ,80) Shore A hardness scale was used. The material of workpiece was Aluminum (3003) with three different thicknesses of (0.8,1,1.2) mm and three holding time of (0,10,20) seconds. The results demonstrate that, the springback decreases with any increase in the rubber hardness or sheet thickness. In addition, the holding time showed a significant effect only with a harder rubber.