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Improving Deep Drawing Quality of DD13 Sheet Metal: Optimization of Process Parameters Using Box-Behnken Design.

Ilhan Celik1, Abdullah Tahir Şensoy2,3, Gokhan Seven4,5

  • 1Department of Mechanical Engineering, Faculty of Engineering and Natural Sciences, Samsun University, Samsun 55420, Türkiye.

Materials (Basel, Switzerland)
|April 24, 2025
PubMed
Summary

This study optimizes deep drawing parameters for DD13 sheet metal, significantly reducing earing and thinning ratios. Key variables like press speed and pressures were adjusted for improved manufacturing outcomes.

Keywords:
Box–Behnken designParticle Swarm Optimizationdeep drawingresponse surface method

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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Processes
  • Sheet Metal Forming

Background:

  • Deep drawing is a crucial metal forming process with inherent challenges like earing and thinning.
  • Controlling process parameters is vital for optimizing product quality and minimizing defects in deep drawing.

Purpose of the Study:

  • To comprehensively analyze the influence of press descent speed, blank holder pressure, and punch pressure on earing and thinning ratios in DD13 sheet metal.
  • To determine optimal process parameters for minimizing earing and thinning in deep drawing, particularly for high deep drawing ratios (>2).

Main Methods:

  • Utilized the Box-Behnken design (BBD) to establish relationships between process parameters and response variables (earing and thinning ratios).
  • Employed Analysis of Variance (ANOVA) to validate the developed regression models, achieving high R-squared values (0.98 for earing, 0.97 for thinning).
  • Identified optimal parameter settings through regression analysis for both earing ratio minimization and uniform wall thickness.

Main Results:

  • Developed robust predictive models for earing and thinning ratios with high accuracy (R² > 0.97).
  • Determined optimal parameter values: press descent speed (27.38), blank holder pressure (10), and punch pressure (22) for minimizing earing.
  • Achieved optimal settings for uniform wall thickness at press descent speed (26.55), blank holder pressure (10), and punch pressure (22).
  • Reported final earing and thinning ratios of 3.79 and 21.19, respectively, across experimental runs.

Conclusions:

  • Optimizing press descent speed, blank holder pressure, and punch pressure effectively mitigates earing and thinning defects in the deep drawing of DD13 sheet metal.
  • The established models provide a reliable framework for predicting and controlling product quality in high-ratio deep drawing applications.
  • The findings demonstrate that strategic parameter adjustment can significantly overcome the inherent limitations of the deep drawing manufacturing process.