PLANNING FOR CUPPING OPERATIONS (Part II)

First Redraw Operation

Planning for the first redraw operation will follow somewhat the same pattern
as the draw operation. The punch or cup diameter is calculated:
d= drawn cup diameter
d1 =First redraw cup diameter

dd 1
d

x 100 =25%

7.67d 1
x 100=.25
7.67
d1 =5.75 inches
Second Redraw Operation
O The second redraw percentage of reduction must be less than the first
redraw due to more severe work hardening of the metal, plus an even smaller
cup wall area in tension.
O The second redraw cup punch or cup diameter for the example is calculated:

d 1d 2
d1

x 100 = 20%

5.75d 2
5.75

x 100 = .20

d 2 = 4.60 inches
One more redraw is necessary to obtain the final cup diameter of 4.00 inches and
depth of 8.00 inches.
Third Redraw Operation
O The percentage of reduction needed to finish the cup in the final redraw is
calculated:

d2 d 3
d3

x 100 = % reduction

4.604.00
x 100=13
4.60

Secondary Operations
O To complete the cup to the part time design, cutting and forming operations
are usually required. There are some instances where forming is combined
with the final redraws.
Trimming
O Trimming is most often done after the last redraw . Trimming must be done
prior to forming operations that change the contour or size of the trim edge.
Embossing
O Many cup design require embossing type forming operations to complete the
product.
O Embossing can be done in the redraw die as long as it is confined to the
center of the cup bottom.
O Embossments are created by stretching metal in a local area.
Miscellaneous Forming

O Another operation is similar to embossing is the strike operation. When sharp

top and bottom are specified on the finish cup. An additional is used at higher
cost to ease the redraw operation.

Cups are very stout, and are a little wider than they are deep.
Notice the ridges on top of the cup. As the cup is drawn into a
casing, these ridges become more pronounced.

This
draw

draw

The cup
is now
ended
cleaned

is what a cup looks like after passing through the first of three
presses. The cup is now a little taller, and considerably narrower.
The cup then has to be annealed or heated, to relax the grain
structure of the metal enough to continue elongation. The
casing also has to be washed prior to being put through the next
process.

has now passed through the second of three draw presses. The cup
much deeper than it is wide, and is starting to look like a closetube. As with the first draw, the cup will need to be annealed and
again prior to further elongation.

The cup has now reached its total elongated length, and is now
considered a casing. Notice how uneven the top of the casing is.
This is partially due to the grain structure in the side walls of the
cup, as well as cup side wall thickness variations. It should be noted
that it is not usual to see a casing in this form, as it would have been
pinch trimmed prior to exiting the third draw press.

Here we have displayed the ring of brass trimmed off the top of the tube in the last
step. Pinching off the extra material at the top of the tube provides us a perfectly
trimmed-to-length tube ready for the next forming operation. The tube also has to
be washed prior to being advanced onto the next step of the forming process.

Complex Cup Drawing

O Simple cups shape can be bulged, necked, or expanded to satisfy some
product designs. Many times the cup design is such that more complex draws
and redraws are needed to create the contours.
1. Stepped Cups
Have two or more shell or wall diameters.
Stepped parts can be created by partial redrawing.
2. Tapered Cups
Cups are designed having a tapered wall, which represents a portion of
a cone.
Tapered cups can be manufactured by first producing stepped cups,
then the sides are formed to create the tapered shape.
3. Domed Bottom Cups
Occasionally, cups are designed having a hemispherical bottom.
Domed cups are formed with a stretch forming type process.