Experimental and numerical optimization of deep drawing process parameters for square medical container design with the Taguchi method

Abstract Medical containers that sterilize surgical instruments are constantly needed in the healthcare industry. In line with this need, improvements in the fabrication of medical containers are important. Determining the design factors of medical containers fabricated by deep drawing saves time and cost. This study determined, the design factors of square medical containers and experimentally verified the deep drawing process modeled in Abaqus/Explicit finite element (FE) software. Taguchi statistical method was used to reduce the number of experiments. Blank holder force (BHF), punch radius (R P ), die radius (R D ), coefficient of friction between die and blank (µ DB ), coefficient of friction between punch and blank (µ PB ), coefficient of friction between holder and blank (µ HB ) as variable factors while selecting thickness reduction (TR) and maximum punch force (PF) were selected as output parameters. The effect of variable factors on the output parameters was determined by ANOVA analysis. As a result of the examinations, it was deter-mined that TR and PF increased as BHF, µ DB and µ HB values increased, whereas they decreased as R P and R D increased. On the other hand, it was determined that TR decreased and PF increased as µ PB increased. In addition, the corners of the sheets were chamfered in different sizes to prevent the formation of ears in the containers. Finally, the appropriate chamfer size was determined by examining the sheet thicknesses.