Numerical Simulation and Experimentally Investigation into Forming of Cups using Conical Die Based on an Innovative Deep Drawing Combinations Processes
Abd-Eltwab, A., Kandil, S., El-Sheikh, M., Saied, E., Abd-Elhalim, E. (2025). Numerical Simulation and Experimentally Investigation into Forming of Cups using Conical Die Based on an Innovative Deep Drawing Combinations Processes. EKB Journal Management System, 54(2), 146-165. doi: 10.21608/jesaun.2025.400167.1594
Ayman Abd-Eltwab; Sayed Zahran S. Kandil; Mohamed N. El-Sheikh; Essam Khalaf Saied; Eman S. M. Abd-Elhalim. "Numerical Simulation and Experimentally Investigation into Forming of Cups using Conical Die Based on an Innovative Deep Drawing Combinations Processes". EKB Journal Management System, 54, 2, 2025, 146-165. doi: 10.21608/jesaun.2025.400167.1594
Abd-Eltwab, A., Kandil, S., El-Sheikh, M., Saied, E., Abd-Elhalim, E. (2025). 'Numerical Simulation and Experimentally Investigation into Forming of Cups using Conical Die Based on an Innovative Deep Drawing Combinations Processes', EKB Journal Management System, 54(2), pp. 146-165. doi: 10.21608/jesaun.2025.400167.1594
Abd-Eltwab, A., Kandil, S., El-Sheikh, M., Saied, E., Abd-Elhalim, E. Numerical Simulation and Experimentally Investigation into Forming of Cups using Conical Die Based on an Innovative Deep Drawing Combinations Processes. EKB Journal Management System, 2025; 54(2): 146-165. doi: 10.21608/jesaun.2025.400167.1594

Numerical Simulation and Experimentally Investigation into Forming of Cups using Conical Die Based on an Innovative Deep Drawing Combinations Processes

JES. Journal of Engineering Sciences
Article 11, Volume 54, Issue 2, March and April 2026, Pages 146-165    PDF (1.07 M)
Document Type: Research Paper
DOI: 10.21608/jesaun.2025.400167.1594
Authors
Ayman Abd-Eltwab* 1; Sayed Zahran S. Kandil2; Mohamed N. El-Sheikh2; Essam Khalaf Saied3; Eman S. M. Abd-Elhalim4
1Mechanical engineering department faculty of engineering Beni-Suef university, Egypt.
2Mechanical Department, Faculty of Technology and Education, Beni-Suef University, Beni-Suef 62511, Egypt
3Associate Professor, Mechanical Engineering Department, Faculty of Engineering, Beni-Suef University, Beni-Suef 62511, Egypt
4Mechanical Eng. Dep., Faculty of Engineering, Assiut University, Assiut, Egypt
Abstract
Deep drawing process is important sheet metal forming processes and is done either with or without blank holder. In this research, there is another innovative method that combines both two modes drawing process at the same time, with the possibility of ironing the thickness for the wall cup produced in the same process. In the first, drawing is done without a blank holder by two inclusion punches, one of which forms an initial cup. Then it creates an inclined blank holder for the drawn cup, and the other punch continues process, followed by wall thinning completing the deformation of the cup. The ironing happens when using several punches with diameters whose clearance is less than the thickness of the blank. A simulation model of the innovative process was built using the ANSYS program, while experimental work was conducted on a general testing machine, also the study effect of the process variables on the produced cups and their characteristics. The results showed that the innovative process of deep drawing led to an increase in drawing ratio that reached 2.24. This is a high percentage compared to the traditional method, also the process variables have a clear effect on the cups produced. The simulation results showed their convergence was observed between the simulation and experimental results at the same conditions. The results also showed that the values of wall thinning reached by 80% from the thickness blank value before drawing
Keywords
Deep Drawing Process; Cups; Blank holder; Simulation; and Drawing ratio
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