Aim of the Experiment:

To learn the forming characteristics of sheet metal specimens with Deep Drawing operation.

Objective:

i. To do the deep drawing experiment of brass (or any metallic)specimen with the help of a

Compression Testing Machine

ii. To correlate the initial and final dimensions of the job

iii. To determine the deep drawing ratio of the material (given sample)

iv. To determine the deep drawing load (i.e. drawing initiation load and fracture load)

Equipment Used:

i. Deep drawing die, constant clearance Blank holder

ii. Punch

iii. Compression Testing machine,

iv. blank (metallic sample)

v. Torque range

vi. screw gauge,

vii. Vernier caliper

Theory:

Deep drawings sheet metal forming process in which a sheet metal blank is radially drawn into a

forming die by the mechanical action of a punch. It is thus a shape transformation process with

material retention. The process is considered "deep" drawing when the depth of the drawn part

exceeds its diameter. This is achieved by redrawing the part through a series of dies. The operation

is carried out on a pass with punch and dies as shown in Fig.1.Thematerial initially flat flanges of

the blank flows to form the walls of the cup. Due to shrinkage of the outer periphery,
circumferential compressive stress develops which might thicken the sheet or cause local buckling

(wrinkling). The flange region (sheetmetal in the die shoulder area) experiences a radial drawing

stress and a tangential compressive stress due to the material retention property. These compressive

stresses (hoop stresses) result in flange wrinkles (wrinkles of the first order). Wrinkles can be

prevented by using a blank holder, the function of which is to facilitate controlled material flow

into the die radius[1]. For all forming operations, some important solid material’s properties are

involved here.

Ductility is the ability of material to deform undertensilestress; this is often characterized by the

material's ability to be stretched into a wire.

Malleability is the ability of material to deform under compressive stress; this is often

characterized by the material's abilityto form a thin sheet by hammering or rolling Formability is

the ability of material to undergo plastic deformation without being damaged. The mechanical

properties are aspects of plasticity, the extent to which a solid material can be plastically deformed

without fracture.

Deep drawing , this process has been studied intensively by several experiment and investigations.

To overcome difficulties of deep drawing process very thin metal foils were used as new concept.

Required shape and dimensional accuracy where achieved by using auxiliary metal punch together

with polyurethane ring. Another approach use of hot isostatic pressing to form micro channels from

ultra thin foils. Mechanical micro deep drawing process is compared with new laser deep drawing

process through which shock waves are produced. Lubrication is most important as the sheet slide

between die and blank holder. Deep drawing has been carried out with the help of die, blank holder,

punch and sheet metal which is show in below.

Wrinkling in the flange: This defect occurs due to compressive buckling in the circumferential

direction. Due to less blank holding force this defect may occur. Because of the material flow is not

restricted and more material is trying to flow inside the die cavity. Wrinkling in the wall: This defect

takes place when wrinkled flange is drawn into cup or if the clearance is very large, which results in

large unsupported region. Wrinkling is avoided by applying a blank holder force through a blank

holder. This increases friction and hence the required punch load increases. The edges of punch and

die are rounded for the easy and smooth flow of metal. Tearing: This defect occurs because of

high tensile stresses that cause thinning and failure of the metal in the cup wall. Tearing can also occur

in a drawing process if the die has a sharp corner radius. If die radius is too small because of that more

restriction to flow of material. If punch radius too small because of that more thinning of material is

occur at that corner of formed part. Earing: Ears are often wavy projections or unevenness formed

along the edge of the flange or end of the wall of the cup. These are formed due to uneven metal flow
in different directions, which is primarily due to presence of the planar anisotropy in the sheet.

Localized necking: The appearance of any local neck that leads to tearing and failure will obviously

terminate the forming process. This can be considered as local instability that that can be analyzed by

considering a local element. Fracture: it is possible for a plastically deforming element to fracture in

almost a brittle manner. This is not common for sheet used for forming and is often preceded by some

local instability. Basically the quality of deep drawn parts is depended on the better control over metal

flow during process. A blank holder is used to prevent the formation of wrinkle. There should enough

forces on the blank holder to prevent the wrinkles because after winkle is started, the blank holder is

raised from surface of the metal and allow other wrinkles. The force created by the blank holder also

increase frictional forces. Too much blank holder pressure may tear the side wall of the drawn cup,

and also increases tonnage capacity of press tool. Both the condition is not advisable. So, one another

method is used and it is a use of draw bead on die or on blank holder surface.

Fig02:compression testing machine

o Measure the thickness of three blanks (specimens).

o Place ablank at the centre position of the die, put blank holder over it.

o Tighten the blank holder with three bolts, with the help of torque range with 5 N-m

torques.

o Place the punch at its position.

o Now, put the total setup at exact location in the compression-testing machine.

o Restthe load cell on the upper surfaces of the punch.

o Apply the force through the rotating the wheel of the machine until the crack appear on

the specimen

o Unlock the machine and remove the specimen.

o Measure the depth of the specimen that is the ductility of the specimen.

Result

The ductility of the given specimen is 5mm.

References

 Manufacturing Technology, by P N Rao, Second Edition.309-316.

 Mechanical Metallurgy, by George E. Dieter, Third Edition.666 -670.

 Manufacturing Science, by A.Ghosh and A. K. Mallik, 1999, 133-135.

 Technology of Metal Forming Processes, by Surender Kumar, 2008, 120-127.