Deep Drawing Blank Size and Reduction Calculations

Tractrix Curve Graph and Tractrix Die Drawing

Bill of Materials
Item NO Part Name Product Description Treatment Quantity
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Two draws were used in this product due to lower production
costs however it wears the tooling out at a greater rate. The
time saved compared to the tooling costs makes it worth while.
Second Draw 25% Reduction
28.49mm Diameter, 72.48mm High
4063 T4 Aluminium Blank
84.4mm Diameter x 0.2mmThick
First Draw 55% Reduction
37.98mm Diameter, 50.19mm High
Suggested Hight - 65mm
Suggested Diameter - 25mm
Blank Size:
D = d
2
+ (4dh)
D = 25
2
+ (4x5x65)
D = 7,125
D = 84.4mm
Reduction Ratios:
45-65% - 25% - 20% - 16%
55% Reduction:
H = D
2
- ((d
2
/ 4)) / (d)
H = 84.4
2
- ((x37.98
2
/ 4)) / (x37.98)
H = 5992.08 / 119.37
H = 50.19mm
2 Draws is Sufficient
25% Reduction:
H = D
2
- ((d
2
/ 4)) / (d)
H = 84.4
2
- ((x28.49
2
/ 4)) / (x28.49)
H = 6487.51 / 89.50
H = 72.48mm
Finish
Maximum and minimum values put into Tractrix curve calculation excel program, curve was plotted
and transferred onto the die. The process is repeated for the second draw.
Tractrix die made from D-2 tool steel, this is machined and heat treated at 996
o
c. It is then tempered
at 180
o
c for 2 hours to give a final hardness of 62HRc. Tractrix wall made from D-3 Tungsten Carbide
64HRc, this is tempered straight after chrome plating to stop hydrogen embrittlement.
The product is finished in a plastic wrap that can be printed on. This was used as it was more cost
effective and portrayed the branding more effectively by enabling the use of color in the design making
it more noticeable to customers.
This would be a cheap form of manufacturing the advertisement apposed to finishing with a traditional
method such as embossing. The final decal can be seen in the title block.
Deep Drawing Punches
Two deep drawing punches were used to create the coin holder. Punch one for the first draw and punch two for the second, they
fit there respective dies and give enough tolerance to fit an equal wall thickness of 0.1mm through the die, the red line represents
the depth of the draw. Both punches have a hardened tip made from D-6 60HRc, tempered at 300
o
c for 1 hour / 25mm thicness
and left to air cool, the tip also has a 45
o
run off to aid with drawing. The mid section of the punch uses D-3 57HRc tempered at
400
o
c for 1 hour / 25mm thickness and cooled slowly in the air. Pressure plate with a 15
o
chamfer to allow for shock absorbs ion
made from EN24T 45HRc tempered at 500
o
c for 1 hour / 25mm thickness. Components held together with Holo-Krome cap heads
(bottom M10 x 100 and the top M10 x 50).
Drawing Punch Head Temp 300
o
c for 1hr/25mm, Air Cooled
Drawing Punch Mid Section Temp 400
o
c for 1hr/25mm, Air Cooled
Drawing Punch Pressure Plate Temp 500
o
c for 1hr/25mm, Air Cooled
Tractrix Die Heat Treated 996
o
c Temp 180
o
c for 2 hours, Air Cooled
Blank 90mmWide
B&T Mounting Bolster MPF16, 4 Pillar Temp 300
o
c for 1.5hr/25mm, Air Cooled
Cleaned Thoroughly
B&T Riser Bar
D-6 60HRc
D-3 57HRc
Shock Absorbsion EN24T 45HRc
Tractrix Die D-2 62HRc
0.2mmTHK 4063 T4 Aluminium Sheet
40mmTHK P20 48HRc
40mm DIA x 700mm Lg, 5mm x 45
o
Chamfer
B&T Top Bolster Pillar Standard Bush 280 a2 Standard Bush
B&T Top Bolster MPF16, 4 Pillar 40mmTHK P20 48HRc Temp 300
o
c for 1.5hr/25mm, Air Cooled
Mounting Bolster 25mmTHK P20 48HRc Temp 300
o
c for 1hr/25mm, Air Cooled
Hydraulics Bolster 20mmTHK P20 48HRc Temp 300
o
c for 1hr/25mm, Air Cooled
Punch Cap EN24 57HRc Temp 400
o
c for 1hr/25mm, Air Cooled
Tractrix Die Wall Die Wall Tungsten Carbide D-3 64HRc Chrome Plate then Temp 150
o
c 1hr/25mm to Stop Hydrogen Embrittlement
Tractrix Die Shroud Prevents the Die Cracking, P20 48HRc Temp 400
o
c for 1hr/25mm, Air Cooled
Stripper Plate Mild Steel, 43A
Holo - Krome M10 x 100Lg Cap Head
Holo - Krome M10 x 50Lg Cap Head
Holo - Krome M10 x 40Lg Cap Head
Holo - Krome M8 x 20Lg Cap Head
Misc Bolsters Base-Mounting, Mounting-Hydraulic P20 48HRc Temp 400
o
c for 1hr/25mm, Air Cooled
Pierce Punch - Hyrdaulic Initial Shear and Secures for Draw, D-3 57HRc Temp 400
o
c for 1hr/25mm, Air Cooled
Blanking Die 1.6UK Tonne to Shear, D-2 62HRc Heat Treated 996
o
c Temp 180
o
c for 2 hours, Air Cooled
Hyrdaulic Ram Hyraulic Ram to Pierce Punch, 3018Kg to Shear
Mounting Bolster Through to Misc Bolster
Mounting Bolster Through to Riser Bar
Hydraulic Bolster Through to Misc Bolster
Attatchments to the Tractrix Die Shroud
Custom Made Component
Bought in from Holo-Krome
Bought in from Holo-Krome
Bought in from Holo-Krome
Bought in from Holo-Krome
Bought in Part, Laser/Plasma Cut to Correct Dimensions
Bought in Part from Boneham and Turner
Bought in Part from Boneham and Turner
One/Punch
One/Punch
One/Punch
One/Die
One/Die
Constant Feed
1
4
2
1
1
1
2
Two/Die
1
2 of Each (4)
1
1
2
4
2
2
2
24 Stripper Prongs Spring Loaded Stripper Prongs P20 48HRc Temp 400
o
c for 1hr/25mm, Air Cooled 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
21
21
22
20
23
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25 B&T Punch Shank ISO 10242/ Type B Screw in Punch Shank P20 48HRc - M20, 68Lg Temp 400
o
c for 1hr/25mm, Air Cooled
Practicle Tool Drawing
Below shows the practical die set up for the deep draw with the Tractrix die for the first draw inserted into the tool.
This works in a similar way to the theoretical drawing however it is for one off productions and is not suitable for
manufacture purposes.
Theoretical Tool Drawing
Below shows the theoretical tool design, this would be used if the design would be taken to full mass manufacture producing
around 60,000 units before the tooling would need replacing. The drawing is to scale with all component materials listed and
the respective hardnesses. The first image shows the tooling at the start position and the stock being pierced and blanked, the
second shows half way through the draw and the completed draw.
System works by the stock being fed into the tool, a hydraulic ram pierces and blanks the stock where it is held in place, the
punch is forced through the Tractrix die making the first draw. This is pushed all the way through the die and out of the bottom
where the product is removed via stripper prongs. This process is repeated for the second draw.
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