Deep Drawing (also called cup drawing)

Principle of working:
Drawing operation is the process of sheet metal forming a flat piece of material
into a hollow shape by means of a punch which causes the blank to flow into the
die cavity. The depth of draw may be shallow, moderate or deep. If the depth of the
formed cup is up to half of its diameter, the process is called "Shallow drawing". If
thedepth of the formed cup exceeds the diameter it is termed as "Deep drawing".
Parts of various geometries and sizes are made by drawing operation, two extreme
examples being bottle caps and automobile panels.

Holddawn
Punch
Ring

D'e

Figure 1

Stages of Deep drawing:

The different stages in the deep drawing process are shown in the figure la.
 Mechanics of Drawing

Bending
Strargtenng

(1) (2) (3
Bending at Straightening the
die and bent sheet,
Fh: Holding force punch stretching
F: Punch force radius

Wall thickness
Compression and variation: yes
thickening of flange
Wall thinning
maximum at
bottom corner of
(4) (5)
cup (mac 25%)
FIGURE l{a) Stages in deiormation of the work in deep drawng (1) punch makes intual contacC wth work, 2) bending, (G)
straightening, (4) friction and compression, and (5) final cup shape showing efiects cf thinnng in the cup walls Symbols: v=oton ct
punch, F= punch force, f,= blankholder force

As the drawing progresses i.e. as the punch forces the blank into die cavity, the
blank diameter decreases and causes the blank to become thicker at its outer
portions. This is due to the circumferential compressive stress to which the
material element in the outer portions is subjected. If this stress becomes excessive
the outer portions of the blank will have the tendency to buckle or wrinkle. To
avoid this, a pressure pad or blank holder is provided. The holding down of
pressure is obtained by means of springs, rubber pad, compressed air cylinder or
the auxiliary ram on a double action press.

The portion of the blank between the die wall and punch is subjected to nearly
purely tension and tends to stretch and becomes thinner. The portion of the formed
cup which wraps around the punch radius is under tension in the presence of
bending. This part becomes the thinnest portion (zone IV) of the cup. This action is
termed as 'necking' and in the presence of unsatisfactory drawing operation, is
usually the first place to fracture. The outer portions of the blank under the blank
holder become thicker (zone I) during the operation. When these portions are
drawn into the die cavity, 'ironing' of this section will occur if the clearance
beiween the punch die is not enough to accommodate this increased thickness of
the work piece. This ironing is useful if uniform thickness of the product is desired
after the drawing operation.
The total deformation region is divided into different zones as shown in figure lb.

Zone-I
Zone-1I
P
Zone-ili

Zene-I1

Zone-l

Figure (1 b) Cup geometry

Sketch of the hydraulic press used in the present laboratory:
Edge holding

Feed Unload

Press

Figure 2
Deep drawing of metal sheet is used to form containers. A flat blank is formed into
a cup by forcing a punch against the center portion of a blank that rests on the die
Ting.
Applications: The process is used for making beverage cans, ammunition shells
and automobile body panels.
Equipment: punch, blank holder ring, blank, die ring, lubricant oil.
Redrawing:
If required percent reduction of sheet metal is over 50%, the part must be formed in multiple
operations. Redrawing is the subsequent deep drawing of a work that has already undergone
adeep drawing process. By using more than one operation, a greater magnitude of deep
drawing can be accomplished.
The amount of foming of the sheet metal that can be accomplislhed on the first redraw is
less than on the original draw. For the original crawing of the blank 50% reduction is
rarely used during industrial manufacturing practice. The initial reduction is usually 35%
to 45° o. First redraw is com1monly performed at a20% to 30% reduction. Second redrawv
can typically range from 13°% to 16% reduction. If asevere amount of deep drawimg is to
be perfoImed and several redrawing operations are necessary, then the part should be
amealed every two operations. This will recover the material for futher redrawing.
Deep drawing process design must include the drawing of intermediate part shapes. in
situations requiring rerawing. For every redraw to be performed there willbe one
intermediate part.
Final shape of a container can be reached by more drawing steps, these operations
are called as re-drawings. See figure 3

punch for redrawing

blankholder

blank

workpiece
die ring.

Figure 3: Cup which was drawn earlier is kept again for drawing (i.e., redrawing)
 DRAW REDRAW

ORIGINAL
BLANK
INTERMEDIATE
SHAPE FINAL
Figure 3a PART
Intermediate shape design is important and unique tooling and setup will be required for
each intermediate step. Eaclh operation will affect the next one and analysis must be done
for each step. When designing intermediate shapes. the sheet metal reduction should be
cOnsidered and in most cases it can be assumed that the surface area of the blank. any
intermediate shapes and the part. to be the same.
Reverse redrawingg of sheet metal. or reverse drawing,is sometimesused to redraw parts.
In reverse redrawing. the intermediate part is flipped over before being placed on the die
for the next operation. This will cause the sheet metal to now be drawn in the opposite
direction as the first draw.

Combined Drawings:

More drawing operations can be combined into one tool using multiple ram system
in a hydraulic press. See figure 4 below.

required
Figure 4: Two drawings are combined on the blank simultaneously to get the
shape
Lubrication:
One of the most common metalworking methods is drawing, which involves
forming flat sheet metal into "cup-shaped" parts. If the depth of the formed cup is
cqual to or greater than the radius of the cup, the process is called deep drawing.
Deep drawing involves placing a sheet metal blank over a shaped die and pressing
the metal into the die with a punch (see Figure 1). The piece produced may be
cylindrical or box-shaped with straight or tapered sides or with a combination of
straight, tapered, or curved sides.
The punch must provide enough force so that the metal is drawn over the edge of
the die opening and allowed to flow into the die. The sheet metal blank must be
strong and ductile enough to avoid breaking in areas where the metal flows from
the punch face to thesides of the punch.
Characteristic of deep drawing is the high pressure-on the order of 100,000
pounds per square inch (PSI) involved in the operation. To deal with such force,
the choice of lubricant is critical to the success of the operation. Under such
pressure, the drawing lubricant should:
1. Cool the die and the workpiece.
2. Provide boundary lubrication between the die and the workpiece.
3. Prevent metal-to-metal adhesion or welding.
4. Cushion the dieduring the drawing operation.
Drawing compounds used in deep drawing are known as boundary lubricants. The
tooling and sheet metal surfaces are pressed so tightly together that the liquid is
squeezed out and only a very thin adsorbed film remains. This film forms a
"boundary," preventing direct metal-to-metal contact under conditions of high
pressure and temperature produced during the deep drawing operation. Proper
lubrication prevents friction, which causes heating and can ultimately lead to the
breakdown of a lubricant.

Different types of drawing lubricants are used, depending on the depth of a

particular draw. Generally, the effectiveness of a deep drawing lubricant depends
oiliness on the
on its ability to form an adsorbed film of sufficient strength and
metal surface being drawn.
Three types of drawing lubricants are used:
 Drawing oils. Drawing oils form an adsorbed film, and they take the form of
light or soluble oils such as straight mineral oil or emulsions of soluble oil
and soap, or of heavy oils, fats, and greases such as tallow or lard oil.
2. Emulsions. Aqueous solutions of non-oily lubricants containing some
suspended solids are called emulsions. These lubricants are not widely used
in deep drawing because they contain little or no oil.
3. Lubricants containing both oil and solid substances. Used in applications
involving severe drawing, these lubricants contain oily components that
reduce friction and heat. The combination of the oil and the solids together
produces enough lubrication for severe drawing applications such as deep
drawing.
A typical lubricant used for drawing is a soap/fat paste-type material that has a
formulation of 5 percent soap, 25 percent oil, 25 percent water, and 45 percent
solids.
The soap and oil are responsible for forming the adsorbed film between the metal
surface and the die, and the solids include materials such as graphite, chalk, zinc
oxide, carbonates, and borates. that further aid in the forming of the boundary film
between the metal surface and die. The combination of oil, water, and soap helps to
form the emulsion, preventing separation of the product. In addition to these major
components, lubricant formulation can include additives such as defoamers and
biocides.

A ubricant compound can be used as a paste or as a liquid after being iluted with
water, depending on the required concentration and the severity of the drawing
operation. Methods for applying lubricant to sheet metal include dips, swabs,
brushes, wipers, rollers, or recirculation. Of these, the three most common are:
1. Manually wiping lubricant onto a surface with a rag.
2. Rollcoating, during which metal blanks pass through rollers that apply the
compound.
3. Flooding, during which tooling and metal sheets are drenched with lubricant,
and the excess liquid is recovered via a filtration and recirculation system.
Lubricant Removal
Animal fats and petroleum oils have been traditionally used as paste-type products
in deep drawing. Although animal fats are inexpensive components of such
compounds, they can be difficult to remove, even when drawn and formed parts
proceed immediately to a cleaning system. They can also load up and "kill" a
cleaner tank quickly, and difficult-to-dissipate soap foam can form rapidly when
highly alkaline cleaners are used with the compounds.
Removing lubricant from a formed part after the deep drawing operation is
important because any lubricant left behind can interfere with subsequent steps in
the manufacturing of the part. Mincral oils, animal fat, and vegetable oils can be
removed with an organic solvent by emulsification or saponification, or with an
aqueous alkaline cleaner. Greases can also be removed from sheet metal with an
organic solvent or an alkaline cleaner. However, an alkaline cleaner may be slower
in removing the drawing lubricant.
Solids are more difficult to remove because they are not readily soluble. The
presence of solids often requires that additional cleaning methods be used.
Petroleum oils can raise special issues from removal through disposal. These oils
require the use of alkaline cleaners for removal, which can then contaminate
cleaner tanks with oil,leading to potential disposal challenges.
Vegetable oils can be removed with hot water if the parts are cleaned immediately
and with a mildly to moderately alkaline cleaner if the parts are cleaned after they
have been left standing for a few days.
Defects in Deep drawing:
Wrinkling in the flange Fig (a)
Occurs due to compressive buckling in the circumferential direction
(blank holding forceshould be sufficient to prevent buckling.

o Wrinkling in the wall Fig (b)

Takes place when a wrinkled flange is drawn into the cup or if the
clearance is very large, resulting in a large suspended (unsuppoted)
region.

(a) (b)
 o Tearing Fig (c)
High tensile stresses that cause thinning and failure of the metal in the cup wall.
If the dic has a sharp corner radius.

O Earring Fig (d)

When the material is anisotropic
o Varying propertics in different directions.

OSurface scratches Fig (e)

If the punch and die are not smooth (c)
If the lubrication of the process is poor.

(e)

Deep drawing ratio or Limiting drawing ratio(LDR):

It is defined as the ratio of the maximum blank diameter that can be
safely drawn into acup without flange to the punch diameter. It is an indicator of
material formability and deep drawability. The higher the drawing ratio, the more
extreme the amount of deep drawing.
For shapes that are noncircular, the maximum diameter is sometimes used, or
occasionally LDR is calculated using surface areas. Generally, LDR is 2 or under.
"Limiting Drawing Ratio (LDR)
B= DJd,
" where D, is the diameter of the first (largest) blank and d, is the smallest cup
diameter that can be successfully drawn
 " Drawing Ratio in general:
"First drawing B,=2,2...1,8
redrawing B,=1,4...1,1
(copper, aluminium, mild steel)

Reduction
Another way to express drawing ratio is the
same variables as drawing ratio. reduction (r). Reduction is measured using the
Reduction can be calculated by r=(Dy- D,)/(D).
D, and D,being blank and punch
diameters respectively. Reduction should be .5 or nder.
Often expressed as the percent reduction r = (Dy - D,)/(D)X 100%. In
reduction should be 50% or under. this case the

Calculation of blank diameter:

The following assumptions are made while
1. There is no change in thickness even calculating the diameter:
after deep drawing.
2. In case of cup-like components, the blank is circular.
Drawing of a Cylindrical Cup Area of blank egqual to
from a Square Blank the area of cup: d,

D,n _dËz -+d,ah h

4 4

D, =d; +4d,h
Punch
dameter

Blanik
diarneter D)
Preparation of cup using Deep Drawing machine
Aim: To make a cup of Mild Steel material using deep drawing machine

Equipment required:
Hydraulic press or deep drawing machine
Compound die
Progressive die
lubricating oil
" MS blank of 100X100 mm size

Procedure:
1. Set the compound die/ progressive die or deep drawing machine in required
position.
2. Switch the motor on to start the machine.
3. Apply lubricant to the workpiece, blank holder and plunger.
4. Pass the MS sheet in to progressive die in case of deep drawing.
5. Apply injection pressure using direction control valve.
6. The plunger punches the sheet in to the die cavity
7.Release the injection pressu
8. Take out the finished product from the die.
9. Switch off the motor.

Precautions:
1. Wear apron and shoes.
2. Proper lubrication must be done between moving parts.
3. Operate the hydraulicpress carefully.
4. Do not apply too high injection pressure.
Result:
Cup of required shape and size is prepared using a hydraulic press.