DRAWING OF RODS, WIRES AND

PIPES
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
DEEP DRAWING
 Process of making all types of containers such as pots and pans
for food and beverages, stainless steel kitchen sinks, canisters,
and automotive fuel tanks.
 Such parts usually are made by a process in which a punch
forces a flat sheet metal blank into a die cavity.
 In the basic Deep Drawing (DD) process, a round metal blank is
placed over a circular die opening and is held in place with a
blankholder or hold-down ring. The punch travels downward and
forces the blank into the die cavity forming a cup.
 The important variables in DD are:
 The properties of the sheet metal
 The ratio of the blank diameter Do to that of the punch diameter Dp
 The clearance C between the punch and the die
 The punch radius Rp,
 The die corner radius Rd
 The blankholder’s force
 Fiction between and lubrication between all contacting surfaces 44
 C

Figure 1 – Deep Drawing Tool Setup

45
 During the DD operation, the blank’s movement into the die
cavity induces compressive circumferential (hoop) stresses in
the flange which tend to cause the flange to wrinkle during
drawing.
 Wrinkle can be reduced or eliminated if a blankholder is kept
under a force whose magnitude can be controlled as a function
of punch travel
 The max punch force in DD can be estimated as
Do
Fmax = D p ho (UTS )[( ) − 0 .7 ]
Dp
 The force increases with increasing in blank diameter,
thickness, strength and the ratio (Do/Dp).
 The wall of the cup is subjected principally to a longitudinal
(vertical) tensile stress due to the punch force. Elongation
under this stress causes the cup wall to become thinner and if
excessive, can cause tearing of the cup

46
 To avoid tearing, the following factors have to be
obeserved:
 Proper design and location of drawbeads

 Large die radii

 Effective lubrication

 Proper blank size and shape

 The use of blanks free of internal and external

defects
 Proper cutting off of corners of square or
rectangular blanks at 45 to reduce tensile
stresses developed during drawing.

47
48
49
Defects in Deep Drawn Components

50
REFERENCES
• Dieter, G.E., Mechanical metallurgy, 1988, SI metric edition,
McGraw-Hill, ISBN 0-07-100406-8.
• Edwards, L. and Endean, M., Manufacturing with materials,
1990, Butterworth Heinemann, ISBN 0-7506-2754-9.
• Beddoes, J. and Bibbly M.J., Principles of metal
manufacturing
process, 1999, Arnold, ISBN 0-470-35241-
• Tapany Udomphol (2007): Lecture Not – Drawing of Rods,
Wires and Tubes Suranaree University of Technology, Jan-
Mar 2007

51