Practicle Tool Drawing Deep Drawing Punches Deep Drawing Blank Size and Reduction Calculations

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.
Two deep drawing punches were used to create the coin holder. Punch one for the first draw and punch two for the second, they Two draws were used in this product due to lower production
fit there respective dies and give enough tolerance to fit an equal wall thickness of 0.1mm through the die, the red line represents costs however it wears the tooling out at a greater rate. The
the depth of the draw. Both punches have a hardened tip made from D-6 60HRc, tempered at 300oc for 1 hour / 25mm thicness time saved compared to the tooling costs makes it worth while.
and left to air cool, the tip also has a 45o run off to aid with drawing. The mid section of the punch uses D-3 57HRc tempered at
400oc for 1 hour / 25mm thickness and cooled slowly in the air. Pressure plate with a 15o chamfer to allow for shock absorbs ion
made from EN24T 45HRc tempered at 500oc for 1 hour / 25mm thickness. Components held together with Holo-Krome cap heads
(bottom M10 x 100 and the top M10 x 50).

4063 T4 Aluminium Blank First Draw 55% Reduction Second Draw 25% Reduction
84.4mm Diameter x 0.2mm Thick 37.98mm Diameter, 50.19mm High 28.49mm Diameter, 72.48mm High

Suggested Hight - 65mm Reduction Ratios: 2 Draws is Sufficient

Suggested Diameter - 25mm 45-65% - 25% - 20% - 16%
25% Reduction:
Blank Size: 55% Reduction: H = D2 - ((πd2 / 4)) / (πd)
D = √d2 + (4dh) H = D2 - ((πd2 / 4)) / (πd) H = 84.42 - ((πx28.492 / 4)) / (πx28.49)
D = √252 + (4x5x65) H = 84.42 - ((πx37.982 / 4)) / (πx37.98) H = 6487.51 / 89.50
D = √7,125 H = 5992.08 / 119.37 H = 72.48mm
D = 84.4mm H = 50.19mm

Tractrix Curve Graph and Tractrix Die Drawing Finish

Maximum and minimum values put into Tractrix curve calculation excel program, curve was plotted The product is finished in a plastic wrap that can be printed on. This was used as it was more cost
and transferred onto the die. The process is repeated for the second draw. effective and portrayed the branding more effectively by enabling the use of color in the design making
it more noticeable to customers.
Tractrix die made from D-2 tool steel, this is machined and heat treated at 996oc. It is then tempered
at 180oc for 2 hours to give a final hardness of 62HRc. Tractrix wall made from D-3 Tungsten Carbide This would be a cheap form of manufacturing the advertisement apposed to finishing with a traditional
Theoretical Tool Drawing 64HRc, this is tempered straight after chrome plating to stop hydrogen embrittlement. method such as embossing. The final decal can be seen in the title block.
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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Bill of Materials
21 Item NO Part Name Product Description Treatment Quantity
1 Drawing Punch Head D-6 60HRc Temp 300oc for 1hr/25mm, Air Cooled One/Punch
2 Drawing Punch Mid Section D-3 57HRc Temp 400oc for 1hr/25mm, Air Cooled One/Punch
13 21 3 Drawing Punch Pressure Plate Temp 500oc for 1hr/25mm, Air Cooled One/Punch
Shock Absorbsion EN24T 45HRc
4 Tractrix Die Tractrix Die D-2 62HRc Heat Treated 996oc Temp 180oc for 2 hours, Air Cooled One/Die
5 Tractrix Die Wall Die Wall Tungsten Carbide D-3 64HRc Chrome Plate then Temp 150oc 1hr/25mm to Stop Hydrogen Embrittlement One/Die
1 8 6 Blank 90mm Wide 0.2mm THK 4063 T4 Aluminium Sheet Cleaned Thoroughly Constant Feed
7 B&T Mounting Bolster MPF16, 4 Pillar 40mm THK P20 48HRc Temp 300oc for 1.5hr/25mm, Air Cooled 1
8 B&T Riser Bar 40mm DIA x 700mm Lg, 5mm x 45o Chamfer Bought in Part from Boneham and Turner 4
9 B&T Top Bolster Pillar Standard Bush 280 a2 Standard Bush Bought in Part from Boneham and Turner 2
10 B&T Top Bolster MPF16, 4 Pillar 40mm THK P20 48HRc Temp 300oc for 1.5hr/25mm, Air Cooled 1
12 11 Mounting Bolster 25mm THK P20 48HRc Temp 300oc for 1hr/25mm, Air Cooled 1
20 12 Hydraulics Bolster 20mm THK P20 48HRc Temp 300oc for 1hr/25mm, Air Cooled 1
13 Punch Cap EN24 57HRc Temp 400oc for 1hr/25mm, Air Cooled 2
14 Tractrix Die Shroud Prevents the Die Cracking, P20 48HRc Temp 400oc for 1hr/25mm, Air Cooled Two/Die
15 Stripper Plate Mild Steel, 43A Bought in Part, Laser/Plasma Cut to Correct Dimensions 1
19 16 Misc Bolsters Base-Mounting, Mounting-Hydraulic P20 48HRc Temp 400oc for 1hr/25mm, Air Cooled 2 of Each (4)
17 Pierce Punch - Hyrdaulic Initial Shear and Secures for Draw, D-3 57HRc Temp 400oc for 1hr/25mm, Air Cooled 1
18 4 18 Blanking Die 1.6UK Tonne to Shear, D-2 62HRc Heat Treated 996oc Temp 180oc for 2 hours, Air Cooled 1
19 Hyrdaulic Ram Hyraulic Ram to Pierce Punch, 3018Kg to Shear Custom Made Component 2
20 Holo - Krome M8 x 20Lg Cap Head Attatchments to the Tractrix Die Shroud Bought in from Holo-Krome 4
6 15 21 Holo - Krome M10 x 40Lg Cap Head Hydraulic Bolster Through to Misc Bolster Bought in from Holo-Krome 2
5 17 22 Holo - Krome M10 x 50Lg Cap Head Mounting Bolster Through to Riser Bar Bought in from Holo-Krome 2
23 Holo - Krome M10 x 100Lg Cap Head Mounting Bolster Through to Misc Bolster Bought in from Holo-Krome 2
11 16 24 Stripper Prongs Spring Loaded Stripper Prongs P20 48HRc Temp 400oc for 1hr/25mm, Air Cooled 2
25 B&T Punch Shank ISO 10242/ Type B Screw in Punch Shank P20 48HRc - M20, 68Lg Temp 400oc for 1hr/25mm, Air Cooled

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14 Pound 4 Pound Deep Drawn Coin Storage

Tel: +44(0) 7817913649

Email: N0293472@my.ntu.ac.uk
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