Adaptive Blank Holder Control Deep-Drawing Process Using Vibration Tooling Without Lubricant

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In order to develop a novel deep drawing process with high flexibility and high product quality achieving no lubricant forming process (so-called "dry forming process") or without cleaning oil process, adaptive blank holder control method combined with vibration tooling technique was studied in this project for two years. The following conclusions were obtained in this study.(1) First of all, a newly developed adaptive blank holder force (BHF) control system was renewed and developed, whose computer was replaced to PC/DOS machine and its interface was also changed into a new one with high accuracy and resolution, and high-speed.(2) Using this machine, a deep-drawing test with low vibration blank holder was carried out under no lubricant for a steel sheet (SPCD) with 1.0mm thickness. As a result, it is clarified that the forming force and forming energy decrease more in the case of large vibrating amplitude of BHF than those of high vibrating frequency. The result implies that the product is capable to have high quality of product surface.(3) To confirm the effectiveness of FEM simulation for the vibrating BH deep-drawing process, the dynamic explicit finite element method was employed, PC/LS-DYNA.The results of simulation are in good agreement with the experimental results. The result shows that the FEM simulation is a good design tool to predict the suitable vibration conditions and to evaluate in advance the fuzzy adaptive BHF control system with vibration and the effect of vibration.