Hydro-mechanical deep drawing is an advanced process in metal forming in which high pressure fluid is used to form complicated parts. Conical parts are kind of complex parts in which there is a high possibility of thinning and rupture during the forming process due to low contact area between the punch head with the blank. In this paper, the Hydro-mechanical deep drawing of Al3003-IF Steel two-layer conical parts is studied using the experimental and numerical approaches. The effects of process parameters such as friction coefficient, arrangement of layers and thickness ratio of two-layer sheet on working zone are investigated. Allowable working zone in this process indicates the applicable range of chamber pressure and drawing ratio to achieve a part without rupture. The results show that with decreasing the friction between blank and blank holder, increasing the friction between blank and punch, increasing the thickness of high formable layer and setting IF steel layer as outer layer increase the limit drawing ratio and make the allowable working zone more extensive. Finally comparison of the results obtained from experimental investigation and numerical simulation shows a good agreement between the results.

Keywords: Hydro-mechanical deep drawing, Two-layer sheet, Conical part, finite element method, Safe working zone

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