Bulk Deformation Processes

Lecture#6:
Deep drawing process

Dr Supratik Mukhopadhyay
Department of Mechanical Engineering
IIT Kanpur
 Deep drawing process

In this process, a cup shaped product is obtained from a flat sheet metal with the help of a
punch and a die. The sheet metal is held over the die by means of a blank holder to avoid
defects in the product.

*Groover, Fundamentals of Modern Manufacturing Processes, Wiley

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 Deep drawing of a stainless steel frying pan

https://www.youtube.com/watch?v=Ag53ek5NLw0

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 Drawing Ratio (DR)

▪ Amount of drawing performed on a sheet metal blank can be

quantified with drawing ration (DR).
▪ Higher the drawing ratio, more extreme is the deep drawing
process.

𝐷𝑜
▪ The drawing ratio is calculated as:
𝐷𝑝

▪ The limiting drawing ratio (LDR) is defined as the maximum

drawing ratio up to which the blank can be drawn without
causing failure/fracture.

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 Drawing bead and metal flow

Draw beads are often necessary to control metal flow into the die cavity. They are placed between the
blank holder and die surface. The flow is regulated by successive bending and unbending operation as the
metal sheet moves past the draw bead. They are particularly necessary when box-shaped or parts without
circular symmetry are drawn, where different regions undergo different deformation (and hence metal
flow at different rate ) during drawing.

(a) Schematic of drawing bead (b) Metal flow during drawing of a box-shaped part, with beads to control metal
flow (c) Deformation of circular grids during drawing

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 Conventional and reverse redrawing

When the required ratio of blank diameter to cup diameter is large, deep drawing is carried out in
multiple steps. The successive operations after the first one are known as redrawing. Usually
annealing is used before each redrawing operation to relieve stresses.

Conventional redrawing Reverse redrawing

(Sheet bends in opposite direction along the blank (Sheet bends in same direction along the blank holder
holder and die corners, more severe deformation) and die corners, less severe deformation)

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 Products of deep drawing

Automobile parts
Rocket nose cone

Household cookware Beverage cans

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 Some other sheet metal forming operations

Conventional spinning
▪ In the spinning process, an object with
surface of revolution is produced from a
sheet metal.
F_hold
▪ The blank is held against a form
die/mandrel which is rotated and the
sheet metal blank is laid over this die
using a specially shaped tool or roller.

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 Some other sheet metal forming operations

Shear spinning
▪ It is the spinning process with simultaneous thinning of the sheet metal during the process.

Shear spinning a conical part Tube spinning

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 Some other sheet metal forming operations

Stretch forming
▪ In a sheet metal bending operation, compressive
stresses are always developed.
▪ Large compressive stresses may lead to local buckling /
wrinkling
▪ Such problems can be avoided by simultaneous bending
and stretching → Stretch forming

Image source: https://www.metalformingmagazine.com

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 Mechanical analysis

Objective:
▪ To determine the drawing force 𝐹.
▪ To correlate the initial and final dimensions of the job.

Assumptions:
▪ No thinning of the sheet during drawing is considered.
▪ The coefficient of friction 𝜇 between the job and the die is constant.
▪ The shear yield strength 𝛫 is constant and taken as the average of its
values at the beginning and end of deep drawing.

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 Mechanical analysis

𝐹
𝐹⟹ Punch force Punch
𝐹h ⟹ Blank holder force Blank holder 𝑟p
𝑟p ⟹ Radius of punch
𝐹h 𝐹h
𝑟cp ⟹ Punch corner radius 𝑐
Job
𝑐⟹ Clearance between punch and blank holder 𝑟cp
𝑡
𝑟j ⟹ Radius of job 𝑟cd
𝑡
𝑡⟹ Thickness of job 𝑟j
𝑟d Die
𝑟d ⟹ Radius of die cavity
𝑟cd ⟹ Die corner radius

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 Mechanical analysis

▪ Due to thickening near the rim (compressive hoop

𝜇𝐹h
stress!), a line contact results between the job and the
𝜎r
blank holder.

2𝜇𝐹h 𝜇𝐹h
𝜎𝑟 ቚ =
𝑟=𝑟j 2𝜋𝑟j 𝑡 𝜎𝜃
𝑑𝑟 𝜎r + 𝑑𝜎𝑟
▪ Considering radial equilibrium of a differential element: 𝑑𝜃 𝑟
𝑑𝜃 𝑡
𝜎𝑟 + 𝑑𝜎𝑟 𝑟 + 𝑑𝑟 𝑡𝑑𝜃 − 𝜎𝑟 𝑟𝑡𝑑𝜃 − 2𝜎𝜃 sin 𝑡𝑑𝑟 = 0 𝜎r
2 𝜎𝜃
𝑑𝜎𝑟 𝑟 + 𝜎𝑟 𝑑𝑟 − 𝜎𝜃 𝑑𝑟 = 0 𝑧

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 Mechanical analysis

The three principal stresses on the differential element are:

𝜎I = 𝜎𝑟 (+ve) 𝜎II = 𝜎𝜃(-ve) 𝜎III ≈ 0(line contact at rim)

Applying Tresca’s yield criterion (Von Mises makes the analysis complex, hence Tresca)

1 1
𝜎max − 𝜎min = 𝜎𝑟 − 𝜎𝜃 = 𝐾
2 2

𝑑𝑟 𝑑𝜎𝑟
Putting 𝜎𝜃 in equation for radial equilibrium: + =0
𝑟 2𝐾

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 Mechanical analysis

Integrating,
𝜎𝑟
= 𝐶 − ln 𝑟
2𝐾

At 𝑟 = 𝑟𝑗 ,
2𝜇𝐹h 𝜇𝐹h 𝜎𝑟 𝜇𝐹h 𝑟𝑗
𝜎𝑟 = ⟹𝐶= + ln 𝑟𝑗 ⟹ = + ln
2𝜋𝑟j 𝑡 2𝜋𝑟j 𝐾𝑡 2𝐾 2𝜋𝑟j 𝐾𝑡 𝑟

𝜎𝑟 𝜇𝐹h 𝑟𝑗
Radial stress at the beginning of die corner 𝑟 = 𝑟𝑑 ⟹ ฬ = + ln
2𝐾 𝑟=𝑟𝑑 2𝜋𝑟j 𝐾𝑡 𝑟𝑑

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 Mechanical analysis

Digression: Belt pulley relationship in presence of friction

𝑑𝜃 𝑑𝜃
Considering horizontal equilibrium: σ 𝐹𝑥 = 0 𝑇 + 𝑑𝑇 cos −𝑇cos − 𝜇𝑁 = 0
2 2
𝑑𝜃 𝑑𝜃
Considering vertical equilibrium: σ 𝐹𝑦 = 0 𝑇 + 𝑑𝑇 sin +𝑇 sin =𝑁
2 2
𝑑𝜃 𝑑𝜃 𝑑𝜃 𝑑𝑇 𝑇2
sin ≈ ; cos ≈1⟹ − 𝜇𝑑𝜃 = 0 ⟹ = 𝑒 𝜇𝜃 (Integrating between limits)
2 2 2 𝑇 𝑇1
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 Mechanical analysis

The deep drawing radial stress up to 𝑟 = 𝑟𝑑 is already obtained.

As the job slides down the die corner, the stress further increases due to friction.
This stress is estimated approximately using a belt-pulley analogy 𝜎𝑟 ቚ
𝑟=𝑟𝑑
𝜎𝑍 𝜇
𝜋
=𝑒 2 𝑟𝑑 + 𝑟𝑐𝑑 ≈ 𝑟𝑑
𝜎𝑟 ȁ𝑟=𝑟𝑑 𝑂

The blank holder force 𝐹h can roughly be estimated 𝑟𝑝

Friction
by: 𝐹h = 𝛽𝜋𝑟𝑗2 𝐾 with 𝛽 = 0.2~0.8
𝜎𝑧
𝑡
The deep drawing force therefore is: 𝐹 = 𝜎𝑧 2𝜋𝑟𝑝 𝑡
𝑧

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 Numerical examples

outside

inside
∧

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 Numerical examples

30 -3 =27

𝑟𝑑 56441 N
𝑡 𝑟𝑝

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 Deep drawing defects

Flange and wall wrinkles

These are wavy surfaces formed in the flange or in the wall of the final drawn part. These appear
due to compressive hoop stress generation due to insufficient blank holding pressure

Flange wrinkle Wall wrinkle

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 Deep drawing defects

Directional earing
The height of the drawn cups have peaks and valleys called earing. Earing results from planar anisotropy.

Ear formation along the rim of a drawn cup

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 Deep drawing defects

Fracture at the rim and bottom

Fracture happens at the base if the tensile stress of drawing is excessively high and exceeds fracture strength
of the material. If a low die corner radius is provided and/or blank holder pressure is very high, the local
stress concentration will cause fracture at the rim.

Cracked rim and base

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 Deep drawing defects

Miss strike
Initial misplacement of the stock with respect to the punch and/or die results in unsymmetrical flanges,
knows as miss strike .

Miss strike in a drawn cup

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 Deep drawing defects

Orange peel
This is a kind of cosmetic defect resulting in a dull surface (higher surface roughness) in the finished
product. If the individual grains of the original blank are too coarse, the grains tend to deform
independently of each other during deep drawing, rather than orienting along the drawing direction,
and results in a surface texture that looks similar to the skin of an orange.

Surface without orange peel Surface with orange peel

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