Study of Deep Drawing Combined with Ironing of A7075 Aluminum Alloy

This study focuses on the process analysis and pass design of compound deep drawing with ironing processes of A7075 aluminum alloy. At first, A7075-T6 aluminum alloy workpiece is annealed to enhance the formability. A compression test is used to obtain its flow stress and critical damage value of annealed A7075 aluminum alloy at room temperature. Finite element simulations are conducted to analyze the plastic deformation of A7075 aluminum alloy in compound deep drawing with ironing processes. Normalized Cockroft-Latham fracture criterion is used to predict material fracture occurrence. A multi-pass compound deep drawing with ironing processes with optimized thickness reductions is conducted to obtain high-drawing-ratio aluminum alloy cups. Finally, experiments of compound deep drawing with ironing processes are conducted. The simulation results of thickness distribution are compared with experimental values. An aluminum alloy cup with an aspect ratio of 2.7 was achieved.