Numerical investigation of the effect of punch corner radius and die shoulder radius on the flange earrings for AA1050 and AA1100 aluminum alloys in cylindrical deep drawing process

In aeronautic sectors, lightweight materials are very demanded in order to reduce fuel consumption. Therefore, thinning drawn cups are very recommended. Reduction of thickness led to many geometrical and physical failures that damage the final product. Since most lightweight materials had a high level of anisotropic, the presence of earrings is one of the most significant failures faced in the deep drawing process. Many functions were developed in order to control these undesirable earrings in sheet metal parts. In this paper, a simulation of a 3D cylindrical deep drawing model for AA1050 and AA1100 aluminum alloys using ABAQUS finite element software was achieved. Prediction of earing phenomenon in deep drawing process was carried out. Moreover, the impact of punch corner radius and die shoulder radius on flange earrings was analyzed and a reduction of the percentage of earring heights was investigated.