Drawing

Q1: What is the result when the radius on the drawing ring is too
sharp and too large?
 If the draw radius is too small (sharp) it will hinder the normal flow of the
metal and uneven thinning to the cup wall and tearing.
 If draw radius is too large the metal will released by blank holder too soon
and wrinkling will result.
Q2: What is the result when the radius on the punch is too sharp
and too large?
 Sharper radius may require higher forces and may result in excessive tearing
or thinning at bottom of the cup. How can we avoid this?? By making
punch radius from 4 to 10 times the metal thickness.
Q3: What will be the result if blank -holder pressure is too high?
 It increases the friction force on the blank which may cause tearing of the
side walls of the drawn cup.
Q4: What are the different between (Single and double -action draw
dies)?

Single -action draw dies

 Double -action draw dies

Q5: True or false and why:

1) In drawing too large die radius may reduce the formation of wrinkles in the
metal (false)
 In drawing too large die radius may INCREASE the formation of wrinkles in
the metal
2) In drawing extra metal should be added because of non -uniformity of
pressure applied (false)
 In FORMING extra metal should be added because of non -uniformity of
pressure applied
3) The hard and less ductile the metal , the slower the drawing speed must be
(true)
Notes:
 Drawing speed is the velocity at which punch penetrates the workpiece
 Low carbon is drawn from 30 to 50 fpm.
 Nonferrous work metal is drawn from 150 to 200 fpm.
 The harder and less ductility the material is the slower the drawing speed must be.
 When cracks and thinning occurs the drawing speed must be reduced.

4) Percent reduction and depth of draw depends upon the thickness of blank
and diameter of shell (true)
Notes:
  The percent reduction in drawing cylindrical shells is generally expressed in
terms of the diameter of the blank D and the drawn shell d 𝑃=100(1−𝑑/𝐷)
5) Drawing process depending on the shape of the work piece thickness and
type of metal (true).
Notes:
 During this operation there are changes in metal thickness and metal flow because there are
more than one draw.

Q6: what is the die clearance of a drawing die?

 It is the gap left between the punch and the die to allow the material of the
workpiece to flow.
Q7: What are the factors affect the selection of grade and quality of
law -carbon steel sheets for deep drawing?
The factors affect the selection of grade and quality of law -carbon steel sheets for
deep drawing are:
1) Severity of draw as determined by the amount of reduction and punch nose
radius.
2) Thickness of sheet
3) Shape of part (round ,rectangular ,or conical)
4) Flange requirements
5) Ironing requirements
6) Desired finish
7) Grain size
8) Press speed
9) Availability of material
10) cost
Q8: Why is it necessary to anneal the work piece between each
drowns?
 To reduce the yield strength or increase the ductility of the material to be
drawn
 To increase the drawability of the metal to be drawn and avoid cracking.
 It is necessary to anneal some metals before they can be redrawn, especially
between the third and the forth draw.
 This necessity depends on the work hardening characteristics of the material.
Annealing must be controlled or it will impair drawability.
Q9: What type of lubricants are generally used and when extreme
pressure applied? Discuss the effect of improper lubricant?
Types of generally lubricants:
State of applied pressure Lubricant type
Straight mineral oil-general purpose
Low pressure
soluble oil-diluted soap solution
Lubricants containing sufficient
Medium-large pressure oiliness polar material (fatty oils-
waxes-concentrated soaps)
The rise in temperature reduce the
Very high pressure
adhering of lubricant

 Some form of extreme pressure lubricant is then required if welding between

the tool and work surfaces is to be avoided. Welding is evidenced by metal build
up on the punch and die causing scratch marks on the work piece.
 Improper lubricants may results in a tearing the metal, wrinkling, bucking and
other causes for rejecting of the work.
Q10: Explain in details the role of lubrication in drawing operation?
Due to the static friction between the work piece and draw-die surfaces must be
overcome in a drawing operation a lubricant is applied to reduce that friction.
Shallow draws in light stampings can be produced with little or no lubricants,
but when forces become larger and scoring, wrinkling and tearing become a
problem a lubricant is always used.
Q11: What are the factors that affect metal flow during drawing
operations? Or what are the variables that affect metal flow during
drawing?
1) Radius of punch
2) Draw radius on die
3) Friction
4) Material to be drawn
5) Percent reduction and depth of draw
6) Drawing speed
7) Depth of draw
Q12: What is meant by ironing when discussing drawing
operations?
Die clearance is the gap between the punch and die to allow for the metal to flow.
When clearance is equal to the metal the metal thickness or less, ironing of the
metal occur near to the top of the cup.

Ironing process
Q13: What are the three principals classes for available low-carbon
steel sheet for drawing operations?
The three principals classes for available low-carbon steel sheet for drawing
operations are:
1) commercial quality
2) drawing quality
3) Aluminum -killed in order to increase drawability.
Q14: What are the characteristics of the material to be drawn have
a great influence on the success of a drawing operation?
The characteristics of the material to be drawn have a great influence on the
success of a drawing operation are: Ductility and yield strength are the most
important.
 Ductility is the ability of the metal to undergo a change of shape without
fracturing.
 Yield strength is the point at which permanent change of shape occurs in a
metal.
A low yield strength and high ductility materials are desirable so that metal
flow be easy without tearing near the punch radius.
Q15: What are the principles causes of wrinkling in deep drawing
process?
One of the primary defects that occurs in deep drawing operations is the wrinkling
of sheet metal material, generally in the wall or flange of the part. The flange of
the blank undergoes radial drawing stress and tangential compressive stress
during the stamping process, which sometimes results in wrinkles.