Deep drawing :

Punch forces a flat sheet metal into a deep die

cavity

Round sheet metal block is placed over a

circular die opening and held in a place with
blank holder & punch forces down into the die
cavity
 Deep drawing process :
Wrinkling occurs at the edges

Process variables in deep drawing. Except for the punch force,F,all the parameters indicated in
the figure are independent variables.
Ex: beverage cans (soda).

How are they made?

Phase 1: a round blank is clamped between a blank holder and

a die with the punch initially placed as seen in the figure: the
punch then pushes the blank into the die cavity.

punch P B
Blank
RP
holder
t RP
die
RD
ri
ri
r0
Variables:
1. Geometry: Blank thickness, t
blank radius, ro
D0
Cup radius, ri
die shoulder radius, RD
LDR0 
punch shoulder radius, RP
Dp
draw ratio,

2. Material: Stress-strain curve

anisotropy
friction coefficient
3. Process: Blank holder force, B
punch force, P
 Consider a frictionless drawing of a rigid-perfectly
plastic sheet:

Y σr=0

r’0
ri
υ
 r  d r

 r 
d
 Summing forces:

   r d r The equilibrium
 equation
r r
We can represent the stress state by Mohr’s circle, stress
normal to the sheet is negligible.

τ
For Tresca Criterion

σϴ σt σr σ  max   min  Y
Equilibrium equation becomes

 Y d r

r r
0 rf dr
 ri
d r  Y 
ri r
 ro 
 ri  Y ln  
 ri 
Deep Drawing
 r0 
For ideal drawing:  r  Y  ln  
 ri 

Calculate force required for drawing

P
 ri 
2    ri  t

ri
P   ri 2    ri  t 
 ri  r0 
P  2    ri  t  Y  ln  ,
 ri 
So, what is the biggest blank I can form for any given size cup?

Pmax  2    ri  t  Y  Y  2    ri  t  ln H max 
P
Y
2ri t

Cancel terms to get:

ln(H)=e=2.718

This assumes perfect plastic material properties

drawn under frictionless conditions
In practice, for the most common metals;

Steel, Hmax = 2.1 to 2.3

Really r0 = 2.1 ri

Hmax = Limit Drawing Ratio, LDR

Example: Consider a sheet with the following properties that will be
deep drawn into a cylindrical cup shape.
t=0.041 in
Y=21000 psi
UTS=385000 psi
K=71000 psi
n=0.27
ri =1.5in
RD =0.375
λ=0.20
μ=0.10

By Experiment, found Pmax = 20000 Ho -20000 LB

Homax =2.2
K n
ln H o n
Flow max stress chosen is: K
Y  
n 1 n 1
Comparing calc. and experimental
results

Ho Pcalc Pexp
1.5 10800 10000
1.75 16400 15000
2.0 22000 20000
2.2 26500 24000
 Deep drawability :

Deep drawability is expressed in LDR

Limiting drawing ratio (LDR)

LDR – Max blank dia/punch dia =Do/Dp

Drawability of metal is determined by normal anisotropy( R )

or plastic anisotropy.

R = width strain / thickness strain =ɛw /εt=ln(w0/wf)/ln(t0/tf)

 Earing or planar anisotropy :

Edges of cups may be wavy this

phenomenon is called Earing

The above condition is called

planar anisotropy

∆ R = (R0 – 2 R45 + R 90 )/ 2
Where ∆ R = 0 => no ears formed
Height of the ears increases as ∆ R
increases.
 Deep drawing Practice :

Blank holder pressure – 0.7% -1.0 % of Yield strength + UTS

Clearance usually – 7% -14 % > sheet thickness

.Ironing is a process in which the thickness of a drawn cup is

made constant by pushing of the cup through ironing rings.

Redrawing – Containers or shells which are too difficult to

draw in one operation undergo redrawing
 Draw beads are used to control flow of blank into die cavity

the rate of material flow into die cavity must be controlled so that a better quality is
maintained and defects like wrinkling, tearing and galling are prevented

Generally the restraining force required to control the material flow is provided by
either the blank holder or the drawbeads. The blank holder creates restraining force by
friction between sheet and the tooling.
When a high restraining force is required, higher binder pressure must be applied to
increase the frictional resistance force, which which may cause excessive wear in the
tooling and galling in strip
In some cases the required binder force may exceed the tonnage capacity of the
press.
Hence a local mechanism is desired which restrains the material flow
sufficiently at relatively low blank holder pressure.

The draw bead consists of a small groove on the die surface / binder surface
matched by protrusion on the binder surface / die surface.
After the binder closure, the sheet metal is drawn over the drawbead and is
subjected to a bending and a subsequent unbending around the entry groove
shoulder, bead and at the exit groove shoulder.
These bending and unbending deformations together with the frictional force
account for the draw bead restraining force.
cup of inner radius Ri, wall thickness t0, and fairly small height H, is first
produced by deep drawing.

The thickness t0 is usually much less than the radius Ri.

Then, during ironing the cup is forced to flow into a conical die of semicone angle
α and inner radius Rf and is pushed downward at a velocity vf by a punch of
radius Ri over which the cup is mounted.

The gap between the die and the punch (Rf -Ri) is the thickness tf: this is the final
thickness of the cup, and tf < t0.

As the punch advances, the wall of the cup extrudes through the gap and its
thickness decreases from t0 to tf while the length H increases.

The outer radius of the cup decreases from R0 to Rf while the inner radius remains
constant at Ri.
Deep drawn cup; t0 << Ri.
Drawing without blank holder :
Deep drawing without blank holder must be provided
with sheet metal which is sufficiently thick to
prevent wrinkling
Range : Do – Dp < 5t
 Lubricants

Lowers forces and increases drawability

commonly used lubricants are mineral oils ,soap

solutions,heavy duty emulsions.

Tooling & equipment for drawing :

Tool & die materials are tool steels cast irons carbides
Equipment is hydraulic press or mechanical press
 Rubber forming :
In bending and embossing of sheet metal , the female
die is replaced with rubber pad

Hydro-form (or) fluid forming process :

The pressure over rubber membrane is controlled
through out the forming cycle ,with max pressure up to
100 Mpi
As a result the friction at the punch-cup interface
increases ,this increase reduces the longitudinal tensile
stresses in the cup and delays fracture
 Bulging :
Process involves placing tabular,conical or curvilinear part into a split-
female die and expanding it
 Segmented die :

Individuals are placed inside the parts and mechanically

expanded in radial direction and finally retracted.

Stretch forming
Sheet metal clamped along its edges and stretched over a
die or form block in required directions.
Stretch forming

Fig: Schematic illustration of a stretch forming process.

Aluminum skins for aircraft can be made by this process
 Spinning :

Shaping thin sheets by pressing them against a form

with a blunt tool to force the material into a desired
form

Conventional spinning :
A circular blank if flat or performed sheet metal hold
against a mandrel and rotated ,while a rigid metal is
held against a mandrel and rotated ,wile a rigid tool
deforms and shapes the material over the mandrel.
 Shear Spinning

Fig 16.40 (a) Schematic illustration of the conventional spinning process (b) Types
of parts conventionally spun.All parts are antisymmetric
 Shear spinning :

Known as power spinning, flow turning, hydro-

spinning, and spin forging
Produces axisymmetric conical or curvilinear shape
Single rollers and two rollers can be used
It has less wastage of material
Typical products are rocket-
motor casing and missile
nose cones.
 Tube spinning :
Thickness of cylindrical parts are reduced by spinning
them on a cylindrical mandrel rollers
Parts can be spun in either direction
Large tensile elongation up to 2000 % are obtained within
certain temperature ranges and at low strain rates.
 Super Plastic forming :
Advantages :
Lower strength is required and less tooling costs
Complex shapes with close tolerances can be made
Weight and material savings
Little or no residual stress occurs in the formed parts

Disadvantages :
Materials must not be super elastic at service
temperatures
Longer cycle times
 Explosive forming :
Explosive energy used s metal forming
Sheet-metal blank is clamped over a die
Assembly is immersed in a tank with water
Rapid conversion of explosive charge into gas generates a shock wave
.the pressure of this wave is sufficient to form sheet metals
Peak pressure (due to explosion):
caused due to explosion , generated in water
P = k( 3sqrt(w) /R)9

P- in psi
K- constant
TNT- trinitrotoluene
W-weight of explosive in pounds
R- the distance of explosive from the work piece
Diffusion Bonding and Superplastic Forming

Fig: Types of structures made by diffusion bonding and super plastic forming of sheet metal.
Such structures have a high stiffness-to-weight ratio.