This research aims to predict the thickness loss of parabolic forming by using hydromechanical deep drawing (HMD) process. The methodology used is the finite element method on the uncertainty of the mechanical properties for 1 mm thickness SPCC sheet metals. The properties consisted of three aspects: strength coefficient (K) strain hardening exponent (n-value) and plastic strain ratio for all three axis (r0 r45 and r90). Multiple simulations were completed by randomly selecting K n r0 r45 and r90 values following the distribution obtained from the uniaxial tensile test. The results would be analyzed by using the regression equation to create the equation to predict the thickness loss of the test pieces obtained from the formation process using the K n r0 r45 and r90 variables without the use of finite element method. This would results in a decrease in the simulation time. Based on 30 experiments of uniaxial tensile test it shows that the sheet metal properties are normally distributed. After that 60 cases of the five variables were randomly selected to simulate the formation by using the finite element method. Finally the results obtained from the aforementioned simulation is analyzed and generated into a regression equation. From the comparison between the value predicted from the regression equation and the result obtained from the formation process it can be seen that the regression equation can effectively predict the thickness loss when the five variables are under the same distribution properties. However the efficiency will decrease when the values of the five variables are beyond the distribution properties obtained from the experiment. In addition the uncertainty of mechanical properties of sheet metal in the simulation displays the chances of discovering test pieces with over 40% thickness loss. The simulation resulted in 5 damaged test pieces accounting for 8.33% of the total process.

The purpose of this research is to find the relation between stress and strain called as the Flow Stress Curve for 0.4 mm thickness stainless steel (SS 304). Two main methods are used: the Uniaxial tensile test and the Hydraulic Bulge Test (HBT). The relation between stress and strain from both methods would then be compared and simulated into cubic-shaped models by using Finite Element method. Results show that sheet metal formation simulated by using the flow stress curve obtained from Hydraulic bulge test can have the height of up to 40 millimeters before the work piece starts to lacerate. On the other hand if the flow stress curve obtained from Uniaxial tensile test is used the work piece will only be able to form about 15 millimeters before lacerating. The preliminary summary for this research can be said that the analysis for Hydraulic bulge test gives better results than Uniaxial tensile test as it has similar conditions to the actual formation process.