The Square cup deep drawing: Technology transfer from experts to increase production in small and medium enterprise (SME) groups
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Apr 7, 2024
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Abstract
The deep drawing is a complex steel forming method involving blank dimensions, dimension/height ratio (D/H ratio), and clearance between die and punch (D/P allowance). Failure to identify proper blank dimensions and D/H ratio can lead to production defects such as tears, while failure to recognize the correct clearance can cause wrinkles. This article discusses technology dissemination to Small and medium-sized enterprises (SMEs) for the deep drawing process in producing R-ornament components #3D40x40, considering these crucial parameters. R-ornament #3D40x40 was manufactured using SPCC-SD material with a thickness of 0.65 mm. The Participatory Action Research (PAR) method was employed to collaboratively optimize blank dimensions, D/H ratio, and dies/punch (D/P) allowance with partners. The optimization of blank dimensions successfully eliminated the need for the trimming process, resulting in reduced investment costs in dies and die setup by IDR 15 million and 2.16 million, respectively. Identifying a D/H ratio of 1.32 successfully eliminated tear defects and determining a D/P allowance of 0.87 mm on each side eradicated wrinkle defects in the product. This article contributes to Goal 9 of the Sustainable Development Goals (SDGs), specifically focusing on the Small and Medium-sized Enterprises (SMEs) sector.
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References
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[29] C. Özek and M. Bal, “The effect of die/blank holder and punch radiuses on limit drawing ratio in angular deep-drawing dies,” The International Journal of Advanced Manufacturing Technology, vol. 40, pp. 1077–1083, 2009, doi: 10.1007/s00170-008-1435-3.
[2] A. Amarulloh et al., “Effect of power and diameter on temperature and frequency in induction heating process of AISI 4140 steel,” Mechanical Engineering for Society and Industry, vol. 2, no. 1, pp. 26–34, 2022, doi: 10.31603/mesi.7121.
[3] S. Saifudin, N. Muhayat, E. Surojo, Y. H. Manurung, and T. Triyono, “Mitigation of Porosity and Residual Stress on Carbody Aluminum Alloy Vibration Welding: A Systematic Literature Review,” Automotive Experiences, vol. 5, no. 3, pp. 477–493, Nov. 2022, doi: 10.31603/ae.7965.
[4] Saifudin, W. Purwanto, and J. C. T. Su, “Characteristics of diamond-like carbon coating using plasma assisted chemical vapor deposition on steel tool,” Automotive Experiences, vol. 3, no. 1, pp. 27–32, 2020, doi: 10.31603/ae.v3i1.3417.
[5] Lutiyatmi and T. Daryanto, “Pengaruh proses degassiing pada peleburan aluminium dengan tungku peleburannya,” Automotive Experiences, vol. 1, no. 3, pp. 70–76, 2018, doi: 10.31603/ae.v1i03.2360.
[6] H. Haikal, M. Chamim, D. Andriyansyah, E. B. Raharjo, A. S. Baskoro, and I. Isnarno, “Effect of Magnetic Field Induce Arc in Autogenous TIG Welding of 304 Stainless Steel Butt Joint,” Automotive Experiences, vol. 4, no. 1, pp. 27–35, Feb. 2021, doi: 10.31603/ae.4199.
[7] S. Sukarman et al., “Tensile shear load in resistance spot welding of dissimilar metals: An optimization study using response surface methodology,” Mechanical Engineering for Society and Industry, vol. 3, no. 2, pp. 66–77, Sep. 2023, doi: 10.31603/mesi.9606.
[8] Japanese Standards Association, JIS G 3141 Cold-reduced carbon steel sheets and strips. 2005.
[9] M. A. Shafaat, M. Abbasi, and M. Ketabchi, “Investigation into wall wrinkling in deep drawing process of conical cups,” Journal of Materials Processing Technology, vol. 211, no. 11, pp. 1783–1795, 2011, doi: 10.1016/j.jmatprotec.2011.05.026.
[10] I. Suchy, Handbook of Die Design, Second. McGraw-Hill, 2006.
[11] A. Abdulah et al., “Diseminasi teknologi metal forming untuk pemberdayaan ekonomi usaha kecil dan menengah,” Community Empowerment, vol. 6, no. 6, pp. 978–986, 2021, doi: 10.31603/ce.4850.
[12] A. Badrish, A. Morchhale, N. Kotkunde, and S. K. Singh, “Influence of material modeling on warm forming behavior of nickel based super alloy,” International Journal of Material Forming, vol. 13, no. 3, pp. 445–465, 2020, doi: 10.1007/s12289-020-01548-x.
[13] M. Özdemir and H. Gökmeşe, “Microstructural Characterization and Deformation of X10CrAlSi24 Sheet Material Applied V-Bending Process,” Tehnički vjesnik, vol. 25, no. 3, pp. 846–854, 2018, doi: 10.17559/tv-20170425022545.
[14] T. Jagadeesha, “Experimental studies in weld nugget strength of resistance spot-welded 316L austenitic stainless steel sheet,” The International Journal of Advanced Manufacturing Technology, vol. 93, pp. 505–513, 2017, doi: 10.1007/s00170-017-0517-5.
[15] M. Kholdi, A. Loghman, H. Ashrafi, and M. Arefi, “Analysis of thick-walled spherical shells subjected to external pressure: Elastoplastic and residual stress analysis,” Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, vol. 234, no. 1, pp. 186–197, 2020, doi: 10.1177/1464420719882958.
[16] K. Khoirudin, M. Murtalim, S. Sukarman, R. H. Anwar, M. A. Rahman, and N. Rahdiana, “Penerapan lemari asap untuk meningkatkan hasil produksi telur asin pada kelompok usaha telur bebek,” in Prosiding Seminar Nasional Pengabdian Masyarakat LPPM UMJ, 2021, vol. 1, no. 1.
[17] K. Khoirudin et al., “A Report on Metal Forming Technology Transfer from Expert to Industry for Improving Production Efficiency,” Mechanical Engineering for Society and Industry, vol. 1, no. 2, pp. 96–103, 2021, doi: 10.31603/mesi.5613.
[18] H. Palaniswamy, G. Ngaile, and T. Altan, “Optimization of blank dimensions to reduce springback in the flexforming process,” Journal of Materials Processing Technology, vol. 146, no. 1, pp. 28–34, 2004, doi: 10.1016/S0924-0136(03)00841-0.
[19] A. Abdulah, R. Kusnadi, M. Rizkiyanto, A. Amir, and D. Setiawan, “An Analysis of the Springback Phenomenon of the Material Aluminum Alloy 6063-T5 With Punch Angle Variation,” Jurnal Teknik Mesin Mechanical Xplore, vol. 3, no. 1, pp. 34–39, 2022, doi: 10.36805/jtmmx.v3i1.2768.
[20] K. Khoirudin, S. Sukarman, S. Siswanto, N. Rahdiana, and A. Suhara, “An Analysis of Spring-back and Spring-go on Variation of V-Dies Bending Angle Using Galvanized SGCC Steel Sheet,” Jurnal Teknik Mesin Mechanical Xplore, vol. 3, no. 1, pp. 17–25, 2022, doi: 10.36805/jtmmx.v3i1.2753.
[21] V. Miguel, J. Coello, A. Calatayud, M. C. Manjabacas, A. Martínez, and C. Ferrer, “An approach to evaluation of sheet bending force under successive multiaxial stress condition,” Journal of Materials Processing Technology, vol. 209, no. 3, pp. 1588–1596, 2009, doi: 10.1016/j.jmatprotec.2008.04.016.
[22] Ş. E. N. Nuri, İ. Çolakoğlu, and V. Taşdemir, “Investigation of deep drawing of square cups using high-strength DP600 and DP800 sheets,” International Journal of Automotive Science And Technology, vol. 5, no. 4, pp. 378–385, 2021, doi: 10.30939/ijastech..995381.
[23] B.-S. Kang, W.-J. Song, and T.-W. Ku, “Study on process parameters and its analytic application for nonaxisymmetric rectangular cup of multistage deep drawing process using low carbon thin steel sheet,” The International Journal of Advanced Manufacturing Technology, vol. 49, pp. 925–940, 2010, doi: 10.1007/s00170-009-2450-8.
[24] M. R. Kurniadi, J. Jatira, R. A. Nanda, R. Kurniawan, O. Jaelani, and D. Setiawan, “Preliminary Study of the Spring-back/Spring-go Phenomenon in the V-Bending Process Using SGCC Steel Thin Material,” Jurnal Teknik Mesin Mechanical Xplore, vol. 3, no. 2, pp. 78–86, 2023, doi: 10.36805/jtmmx.v3i2.3370.
[25] V. Boljanovic, “Sheet metal forming processes and die design,” p. 219, 2004.
[26] T. Altan and A. E. Tekkaya, Sheet metal forming: fundamentals. Asm International, 2012.
[27] Japanese Standards Association, J. G. 3131 Hot-rolled mild steel plated, sheet and strip. 2010.
[28] Japanese Standards Association, JIS G 4404 Alloy Tool Steels. 2015.
[29] C. Özek and M. Bal, “The effect of die/blank holder and punch radiuses on limit drawing ratio in angular deep-drawing dies,” The International Journal of Advanced Manufacturing Technology, vol. 40, pp. 1077–1083, 2009, doi: 10.1007/s00170-008-1435-3.