Finite element analysis of fluid-structure interaction in the hydromechanical deep drawing process

In this work, we attempt to explain the lubrication mechanisms at the blank-die contact zone during the hydromechanical deep drawing process and to simulate such process. An analytical model is proposed for the non-uniform fluid pressure distribution in the cavity and for the hydrodynamic flow of the fluid film between the blank and die. The hydrodynamic flow is calculated by solving the Reynolds equation. The proposed model is implemented in the finite element software ABAQUS/Explicit. After validating the approach, the influences of the blank holder force and the fluid pressure on the formability of the blank metal are investigated using the AA5086 aluminum alloy. The results show that the choice of an appropriate blank holder force can reduce the strain in the blank and prevent the risk of fracture.