Formability Prediction Using Machine Learning Combined with Process Design for High-Drawing-Ratio Aluminum Alloy Cups

Deep drawing has been practiced in various manufacturing industries for many years. With the aid of stamping equipment, materials are sheared to different shapes and dimensions for users. Meanwhile, through artificial intelligence (AI) training, machines can make decisions or perform various functions. The aim of this study is to discuss the geometric and process parameters for A7075 in deep drawing and derive the formable regions of sound products for different forming parameters. Four parameters—forming temperature, punch speed, blank diameter and thickness—are used to investigate their effects on the forming results. Through finite element simulation, a database is established and used for machine learning (ML) training and validation to derive an AI prediction model. Importing the forming parameters into this prediction model can obtain the forming results rapidly. To validate the formable regions of sound products, several experiments are conducted and the results are compared with the prediction results to verify the feasibility of applying ML to deep drawing processes of aluminum alloy A7075 and the reliability of the AI prediction model.