Science, Technology and Development ISSN : 0950-0707

Development of Blank Size for Deep Drawing

of Rectangular Part
Arvind Bodhe
Department of Mechanical Engineering
RTMNU Nagpur, Maharashtra, India
Email- bodhe2013@gmail.com

Pragati Dethe
Department of Chemistry
Science College Pauni, Maharashtra, India
Email- dethepragati@gmail.com

Abstract- Deep drawing, first developed in the Seventeenth century, has studied extensively and become an important
metalworking process. Typical parts produced are beverage cans, pots, pans, containers of all shapes and sizes, sinks, and
automobile panels. This paper aims at deciding the optimum blank shape for final deep drawing of shapes other than
circular by using different available theories. The result of the methods used in this paper will be used as a ready
reckoner for practicing engineers to reduce the number of experiments in trial working. This will also save the time and
material. Numbers of experiments are carried out for suggesting the best possible blank size for rectangular component in
press working.

Keywords – Deep Drawing, Metal forming, Rectangular Blank, Rectangular Parts, Press Work.

I. INTRODUCTION
Deep drawing, first developed in the 1700s, has been studied extensively and become an important metalworking
process. Typical parts produced are beverage cans, pots, pans, containers of all shapes and sizes, sinks, and au-
tomobile panels. To produce a desired shape, the material is formed which is accomplished by straining it beyond
the yield point, so that it will take a permanent shape and retain it [1] . A hydraulic or mechanical press is generally
used for deep drawing work[2].
A sheet metal blank is a flat piece of sheet metal used to form the finished product. The process of deep drawing
begins with a metal blank held on the upper surface of the die. The tooling required to produce the part consists of
a male punch and a female die[3]. Clearance between die and punch should be adequate to allow the flow of
material. The proper blanks gives good results in final parts[4].
II. LIERATURE REVIEW
Deep drawing, first developed in the 1700s, has been studied extensively and become an important metalworking
process. Typical parts produced are beverage cans, pots, pans, containers of all shapes and sizes, sinks, and au-
tomobile panels. To produce a desired shape, the material is formed which is accomplished by straining it beyond
the yield point, so that it will take a permanent shape and retain it [1] . A hydraulic or mechanical press is generally
used for deep drawing work[2]. A sheet metal blank is a flat piece of sheet metal used to form the finished product.
The process of deep drawing begins with a metal blank held on the upper surface of the die. The tooling required
to produce the part consists of a male punch and a female die[3]. Clearance between die and punch should be
adequate to allow the flow of material. The proper blanks gives good results in final parts[4].
V. Gopinathan[5]elaborated the deep drawing processes for circular, rectangular parts. It is mentioned that deep
drawing and deep drawing of special shapes have gained considerable importance in the fabrication of sheet metal
components. It is discussed that for circular deep drawing, the blank is circular whereas for rectangular deep drawing
the initial blank may or may not be rectangular. It may be circular, elliptical or any other shape, depending upon the
drawing ratio and the tool geometry.
Naksoo Kim, Shird Kobayashi [6]described an approximate geometrical method to determine velocity field with
parameters in the deformation domain. It assumed the velocity field in a curvilinear, orthogonal coordinate system.

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The flow lines of material points in the blanks are formulated and the counters of the flange, for the given blank
shape, are determined at several punch steps for the rectangular and square drawing’
S.A. Majlessi, D. Lee [7] suggested a finite element technique. It is suitable for the process of square-cup
drawing. In this type of work, deformation theory of plasticity is adopted. The solution scheme comprises of
specifying a mesh of two-dimensional finite elements with membrane properties over the deformed configuration of
the final part geometry. The initial position of these elements is computed by minimizing the potential energy and
therefore the strain distributions can be determined.
Hideo Iseki, TadaoMurota[8] proposed a finite element procedure for determining the optimum shape and size of
a blank for deep drawing of a non-axisymmetric cup with a flat- headed punch. The optimum blank shapes are
calculated by the repetition method taking account of the strain-hardening characterization of the sheet metal.
Jian Cao ShunpingLi[9]analyzed deep drawing processes of an axisymmetric part with a complex geometry with
the aim of reducing possible forming steps. Their approach combined optimization scheme, design rules and
numerical tests using finite element analysis. The new process design yields a lower maximum void volume. This
indicates more meaningful forming process but requires slightly higher press load. Analytical methods from finite
element are enriched by mesh adaptivity, failure criteria, wrinkling and surface defects, springback and contact
algorithms. It is now possible to simulate new process and design of blank.
Ramamuthy,Rajesh[10] represented an initial step towards the development of a rigorous computer aided tool for
blank design optimization of deep drawn parts. The methodology is based on an optimization formulation whose
goal is to maximize the drawability in the deep drawing process of square shells. Three blank design cases are
studied and compared. The optimal designs obtained from the formulation has better drawability compared to the
drawability of the initial designs in each of the three cases.
Hong Yao,JianCao[11]assessed the corner failure depths in the deep drawing of 3D panels using simplified 2D
numerical and analytical models. Methodologies of rapidly assessing maximum possible forming heights are needed
for three-dimensional (3D) sheet metal forming processes at the preliminary design stage. They proposed to use an
axisymmetric finite element model with an enlarged tooling and blank size to calculate the corner failure height in a
3D part forming.
Neil Krishnan, JianCao[12] estimated the optimal blank holder force trajectory, in segmented binder, using Auto-
Regressive Moving-Average model ARMA model.According to them, variations in blank holder forces also had an
effect on drawing process. If these forces are varied suitable to the process then wrinkle formation and tearing can
avoided.
Suresh K. Sitaraman, Gary L. Kinzel, Taylan Allan[13]described the knowledge-based system and compared
process sequences output by the system with corresponding process sequences from industrial practice. It was found,
through several test cases, that the blank diameter and the number of stations suggested by the knowledge based
system compares well with those used in industrial practice.
X.Q.Peng ,J.Cao[14] applied the homogenization method to determine the effective elastic constants of
unidirectional fiber reinforced composites. Comparison between the obtained results and available experimental data
as well as analytical results from mechanics of materials approach and Halpin-Tsai equations validated the
efficiency and accuracy of die homogenization method in estimating material constants of composites. They applied
this method to determine the material constant of plain woven composite and used them as initial inputs in the
simulation of composite stamping.
Ryutaro Hino, Fusahito Yoshida, Vassili V. Toropov[15] developed the design optimization system by using the
interaction of high- and low-fidelity finite element simulations of a deep drawing process, and the multipoint
approximation technique based on the iterative response surface building.
J.B. Kirn, D.Y. Yang[16]predicted the location and relative possibility of wrinkling initiation by calculating the
wrinkling factor in various sheet metal forming processes such as cylindrical cup deep drawing, spherical cup deep
drawing, and elliptical cup deep drawing. The wrinkling factor proposed in the present study was also implemented
in the prediction of wrinkling in the door inner stamping process. For verification of the calculated wrinkling factor,
detailed zone analyzed with fine meshes were carried out for the regions where wrinkling was predicted.
Hsu, T. C. and Lee, S. Y. [17] showedthat the drawability as measured in the drawing of round cups can be
generalized to cover cups of all possible shapes by a careful analysis of the definition of drawability and that such an
analysis involved the deformation caused by the drawing operation.

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MohdAhmed, G S Sekhon, D Singh[18] proposed finite element simulation of asymmetric sheet forming
operations based on the viscous shell formulation. A computer program named SHEET1d had been developed to
solve the model. The analysis can predict the strain variation and the deformation history of axsymmetric sheet
forming operations.
From the above literature review, it may be concluded that the calculation part of blank is missing. No such work
is identified which can calculate the dimensions for rectangular parts.

III. BLANK CALCULATION AND DEVELOPMENT

It is extremely important to determine the size of the blank for drawing the component accurately and to reduce the
cost. Large blank diameter increases the drawing ratio and may cause cracking. The size of the blank is determined
by knowing the volume of the component to be drawn, which must be equal to the volume of the blank. In most
calculations it is assumed that the sheet thickness remains constant during the (drawing) process. The constant
volume condition is satisfied when the surface area of the blank and the component are equal. This assumption is
correct for simple parts with circular symmetry since both wall thickening and wall thinning occur in these
components such that the mean value of the wall thickness remains approximately constant. In complex shapes,
stretching of sheet due to localized drawing results into thinning and thickening in regular manner.
Followings are some methods which may be used to find the blank size for deep drawing of the rectangular
parts as shown figure 4. (b) -
i) Blank Calculation suggested By Frank Wilson.
ii) Blank Calculation suggested By Daniel Dallas.
iii) Blank Calculation suggested By Prof. Kurt Lange.
iv) Blank Calculation suggested By Dr. S.K. Basu.
v) Blank Calculation suggested By Gopinathan.

Consider a rectangular shell, as shown in figure 4.(a), of dimension that are given as follows:
L =Length =100 mm
W = Width = 50 mm
H = Height of Shell =38 mm
rc= Corner radius =10 mm
rb= Bottom radius =06 mm
Blanks are calculated by various methods and developed for experimentation. Following are some methods
to find the blank size of rectangular shell.

Figure No. 4.(a) Part drawing of Rectangular Deep Draw Part

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Figure 4. (b) Rectangular Pressed Part.

Blanks are worked out using different methods for blank size calculations. Blank lay-out is prepared with the help of
permanent marker, the layout is drawn on the mild steel metal sheet of size of 0.23mm thickness. Different sets of 10
blanks are prepared for each method suggested by Frank Wilson, Daniel Dallus, Prof. Kurt Lange, Dr. S.K. Basu,
V.Gopinathan and method used in company. These blanks are prepared for experimentation.

3.1. Development Of Blank By Frank Wilson Method

For the component mentioned above, corner radius R C can by using equation no 1

RC  2 r c h  rc2  1.41 rc rb  (1)

RC  2 x 10 x 38  10 2  1.41 x10 x 6
R C = 30.73 mm
Hence the blank size of rectangular pare is (182.86 x 132.86) as shown in figure 4.(c)

Figure 4.(c) Blank Shape Of Rectangular Shaped Part By Wilson Method

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Figure 4.(d) Blank By Wilson Method

3.2. Development Of Blank By Dallas
In this method, indicated corner radius is 10 mm. A radius for circular blank for this cylinder of height of
38 mm. is calculated by using equation no. 2. The radius of this circular blank is now used at four corner of the
rectangular blank.
d d 2
2  4dh - 0.5r  (2)
d = 68.12 mm, R=d/2 =68.12/2 , R = 34.06 mm

Figure 4. (e) Blank Shape Of Rectangular Shaped Part By Dallas Method

Figure 4.(f) Blank By Daniel Dallas Method

3.3. Development Of Blank By Kurt Lange

The straight sidewalls are developed into the plane of the bottom. In order to find the shape of the

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Figure 4.(g) Blank Shape Of Rectangular Shaped Part By Kurt Lange Method

Figure 4.(h) Blank By Kurt Lange

3.4. Development Of Blank By Fran Dr. S. K. Basu Method

The blank diameter for this rectangular cup is developed by referring figure 4.(j)

F  AB - 0.86 r   2A  B - 0.86r H - 0.43 r0  (4)

B0  1.27F - 0.5 C  2
0 (5)
B0 =148.58
A0  B 2
0  C02  (6)
A 0  182.87
For obtaining the values of the radii R1 and R2 for the purpose of constructing the ellipse as shown in figure 4.(j),
The radii R1 and R2 are computed as below.

R2 


0.71 x148.58   (7)

 (182.87/14 8.58)2  1 
R 2  70.63 mm
By putting the value of R2

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R1 
A 2
0  B02 - 4  A 0  R 2 
(8)
4(B 0 - 2 R 2 ) 
R 1 =150.27mm
Hence the blank size of rectangular pare is elliptical shape of major axis Ao=182.87mm and minor axis
Bo=1 48.58mm as shown in figure 4.(k).

Figure 4.(i) Blank Shape Of Rectangular Shaped Part By Dr.S.K.Basu Method

Figure 4.(k) Blank By Basu Method

3.5. Development Of Blank By Frank Gopinathan Method

By checking the ratio of the edge radius to breadth (r e /B) and the ratio of breadth to length (B/L). r e /B ratio
is less than 0.25 and B/L ratio is also less than 0.7, hence the blank shape is not circular shape
The constructional procedure for the exact development of blank profile is as follows
Corresponding to the drawing depth, the side length for the radius (r b) is calculated as follows:

l = H + 0.57 rb +06 (10)

l = 38 + (0.57 x 6) +06
l = 47.45 mm
The radius R is calculated as follow.

R  rc2  2H rc - 0.86 rb (rc  0.16 rc )  (11)
R = [(102 +2 x 38 x 10) – 0.86 x 6 (10 + 0.16 x 6)]1/2
R = 28.35 mm

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Figure 4.(l) Blank Shape Of Rectangular Shaped Part By Gopinathan

Figure 4.(l) Blank By Gopinathan Method

3.6. Development Of Blank used in Company

Presently this company is using a rectangular blank of size of 164 mm x 124 mm of mild steel of 0.23mm
thickness

Figure 4.(m) Blank Lay Out With Corner Cut Off Marking

The blanks were prepared by cut off the various shape at corners such as straight cut, concave, convex,
cosine wave, round cut and ‘v’ cut. the sets of 5 specimens each are prepared.

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IV.CONCLUSION
The final parts form the blanks suggested by Wilson method has tearing and earring effects and hence all the parts
were rejected. Out of 198.61 cm2 blank area, 57.48 cm2 trimming area was observed. 28.94% of blank area was
wasted. Hence, this blank is not recommended. The final parts form the blanks suggested byProf. Kurt Lange’s
method had tearing defects. Medium sized wrinkle were observed on the flange. Quality of parts was found to be
poor. Out of 200.54 cm2 blank area, 39.48 cm2 trimming area was observed. Approximately 19.69% of blank area
was wasted as trimming area. Therefore, this method is not recommended. The final parts from the blanks suggested
by Dr.S.K.Basu’s method had tearing defects. Medium sized wrinkles were observed on flange. All parts were
rejected due to shorter length on side flange. Out of 200.16 cm2 blank area, 15.64 cm2 trimming area was
observed.19.69% of blank area was wasted as trimming area. Hence, this method is not recommended. The final
parts from the blanks suggested by Mr. Gopinathan’s method had tearing defects. Medium sized wrinkles were
observed on flange. Only 3 parts out of 10 parts were accepted. Out of 210.45 cm 2 blank area, 37.28 cm2 trimming
area was observed. 17.71% of blank area was wasted as trimming area. Hence, this method is also not
recommended.

REFERENCES
[1] ASTME; ‘Fundamentals of Tool Design’,Prentice Hall of India Ltd.,New Delhi(1964).
[2] Frank Wilson,Philip Harvey; ‘Die Design Handbook’,McGraw Hill ,New York(1964).
[3] ASM; ‘ Metals Handbook, Ninth edition’, 14 Volume, ASM(Ohio).
[4] Daniel Dallas; ‘Tool and Manufacturing Engineers Hand book’, McGraw Hill,New York(1976).
[5] V.Gopinathan; ‘Optimum Blank profile for Rectangular Deep Drawing’Indian Journal of Technology,15,pp.330-333
(1977).
[6] Naksoo Kim, ShirdKoBayashi; ‘Blank Design in Rectangular Cup Drawing by an Approximate Method’,Int.J.Mach.Tool
Des.Res.,26,pp.125-135(1986).
[7] S.A. Majlessi, D. Lee; ‘Deep Drawing of Square Shaped Sheet Metal Parts’ ,Journal of Engineering for Industry,
115,(1993).
[8] Hideo Iseki, TadaoMurota; ‘On the determination of the optimum Blank Shape of Non-axisymmetric Drawn Cup by the
Finite element method’,Bulletin of JSME,29,pp.1033-1040(1986).
[9] Jian Cao,Shunping Li; ‘Analysis of an Axisymmetric Deep drawn part Forming Using Reduced Forming Steps’ Journal
of Materials Processing Technology,
[10] Ramamuthy,Rajesh; ‘Blank Design optimization on Deep drawing of Square Shell’ IIETrasactions , (1998)
[11] Hong Yao,Jian Cao; ‘ assessment of Corner Failure Depths in the Deep Drawing of 3D Panels using Simplified 2D
Numerical and Analytical Model’,ASME Transaction,123,pp. 248-256 (2001).
[12] Neil Krishnan, Jian Cao; ‘Estimation of Optimal Blank Holder Force Trajectiries in Segmented Binders Using an
ARMA Model’. Journal of Manufacturing Science and engineering,125, pp.763- 770 (2003).
[13] Suresh K. Sitaraman, Gary L. Kinzel, Taylan Allan; ‘A Knowledge Based System for process Sequence Design in
Axisymmetric sheet Metal Forming ‘,Journal of Materials Processing Technology,25, pp 247-271(1991).
[14] X.Q.Peng ,J.Cao; ‘Material Characterization in Forming Structural Composites’, Polytechnic University 100th
anniversary Special Issue.
[15] Ryutaro Hino, Fusahito Yoshida, Vassili V. Toropov ; ‘Optimum Blank Design for Deep Drawing Using Interaction of
High and Fidelity Simulation”, ICTAM,21, pp.15-21(2004).
[16] J.B. Kirn, D.Y. Yang; ‘Prediction of Wrinkling Initiation in Sheet metal Forming Processes’ Engineering
Computation,20, pp. 6-39(2002).
[17] Hsu, T. C. and Lee, S. Y.; ‘A Definition of Drawability and its Relation to Deformation in the Drawing of Square
Cups’,4, pp. 340-345(1976).
[18] Arvind B. Bodhe et al,” Comparison and Evaluation of Blank Optimization Technique-A case study”, The 17th International
Conference on Flexible Automation and Intelligent Manufacturing (FAIM’ 2007) held in Malvern, Pennsylvania, USA,
June 18-20, (2007).
[19] Bodhe A.B., Mandavgade N.K., Tajne A. (2019) Selection of Blank Size for Deep Drawing of Rectangular Parts. In: Kolhe
M., Labhasetwar P., Suryawanshi H. (eds) Smart Technologies for Energy, Environment and Sustainable Development.
Lecture Notes on Multidisciplinary Industrial Engineering. Springer, Singapore, pp 663-672.

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