TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables viii
List of Figures ix
List of Abbreviations xii
1. INTRODUCTION 1
1.1 Backgrounds
1 1.1.1
Company 1
1.1.2 Deep Drawing Die
2 1.2
Problem Statement 3
1.3 Objectives
4 1.4
Scope 4
1.5 Structure of the Research
4 1.6
Gantt Chart 6
2. LITERATURE REVIEW 7
2.1 Deep Drawing Process
7 2.1.1 Definition
7 2.1.2 History
9 2.2
Parameters of Deep Drawing Die 11
2.2.1 Properties of Sheet Metal 13
2.2.2 Ratio of Blank Diameter to Punch Diameter 13
2.2.3 Sheet Thickness 14
2.2.4 Clearance between Punch and Deep Drawing Die 15
2.2.5 Blank Holder Force 16
2.2.6 Maximum Force of Punch 17
v
2.2.7 Drawn Cup Height 18
2.2.8 Drawn Cup Diameter 21
2.3 Previous Research
22 2.4
Finite Element Analysis FEA 24
2.4.1 Explicit Dynamic Analysis 27
3. METHODOLOGY 31
3.1 Flow Chart
31 3.1.1 Phase 0: Planning
33 3.1.2 Phase 1: Concept Development
33 3.1.3 Phase 2: Detail Design
33 3.1.4 Phase 3: Analysis Refinement
34 3.1.5 Phase 4: Report Submission Presentation
34 3.2
Process to Produce Brass Socket 34
3.3 Concept Generation
37 3.4 Concept Selection
42 3.5
Material Selection 42
3.6 Workpiece
42 3.7
3D-Modeling 43
3.8 Maximum Punch Force
43 3.9
Drawn Cup Height 46
3.10 Drawn Cup Diameter
48 3.11
Simulation Software 49
4. PROCEDURE OF EXPLICIT DYNAMIC ANALYSIS USING ANSYS 50
4.1 Create Analysis System
50 4.2
Engineering Data 55
4.3 Geometry
57 4.4
Stiffness Behaviour 58
4.5 Define Connections
62 4.5.1 Contact Regions
62 4.5.2 Setting Contact Conditions Manually
65 4.6
Meshing 66
vi
4.6.1 Physics Based Meshing 66
4.6.2 Using 3D Rigid Body Contact Meshing 68
4.7 Establish Analysis Settings
70 4.8
Fixed Support 71
4.9 Displacement
72 4.10
Solve 74
4.11 Review Results
79
5. RESULT 84
5.1 Results for Each Conceptual Design
84 5.1.1 Conceptual Design A
85 5.1.2 Conceptual Design B
92 5.1.3 Conceptual Design C
99 5.1.4 Conceptual Design D
107 5.1.5 Conceptual Design E
114
6. DISCUSSION 121
6.1 Total Deformation
121 6.2
Shear Stress 122
6.3 Proposed Design
123 6.4
Energy Evaluation 124
7. CONCLUSION AND RECOMMENDATION 126
