Articles - Deep Drawing from A to Z | MetalForming Magazine https://www.metalformingmagazine.com/magazine/article/?/2008/7/1/D...

Subscribe | My Online Account

About Us Magazine Multimedia Enterprise Zones Web-Only Content Industry Showcase Advertise

VISI T OUR SP ONS ORS

» home » magazine » 2008 » july 2008 » deep drawing from a to z

Articles
Back Print Article
View the July 2008 Issue Buy Reprints

SHARE:

DEEP DRAWING FROM A TO Z

There are 1 comments | Post a comment
Tuesday, July 1, 2008

<< Previous Page Page 2 of 4 Next Page >>

1:2:3:4

The redraw reduction percentage can never be as

high as the first draw because the redraw has more
bending and straightening forces, the cup wall in
tension is smaller, and the material has been
previously workhardened. Consequently, reductions
for the first redraw usually measure 55 to 60 percent
of the initial draw reduction. For example, given a first
Fig. 6—Achieving a cup with a greater height-to-diameter ratio requires draw reduction of 48 percent, the first redraw
one or more redraw dies. reduction would be 48 percent initial blank reduction
times 0.60, or 29 percent. The next redraw reduction
percentage must be less than the first redraw due to more severe workhardening plus an even smaller cup wall in
tension. As a rule, all subsequent redraw reductions are approximately 10 percent less than the previous redraw.
Thus, given a first redraw reduction of 29 percent, the second redraw reduction would be 26 percent; the third
redraw-reduction percentage would be 10 percent less than the second redraw, a 23 percent reduction; and the
fourth redraw would be 10 percent less than the third, a 21 percent reduction.

Suppose a final reduction is necessary in the fourth

redraw, but requires only a 6 percent reduction. Building
a fourth redraw tool for such a small reduction may not
be cost-effective. Instead, a slight increase in the draw
and other redraw percentages could eliminate the last
redraw die. However, if the process is already critical,
the initial draw and redraw percentages should be
reduced to increase the fourth redraw reduction
percentage and make it worthwhile. This pattern can be
observed in Table 1. Different handbooks provide
somewhat different reduction sequences.

To Fl ang e o r N ot to Fl ange

Two types of redrawing methods are direct redrawing

and reverse redrawing. Direct redrawing reduces cup
diameter by redrawing the cup in the same direction as
the first draw. In reverse redrawing, the cup is inverted during diameter reduction. Regardless of the redrawing
method chosen, a decision must be made to draw the cup in the first draw operation with or without a flange.

Why leave a flange on the first cup draw?

• If the cup is to be produced in a progressive die, a flange may be needed for attachment to the carrier ribbons.

• It keeps the burr on the blank edge, a from the die radius. Drawing the burr down over the die radius can roughen or
scratch the die radius, eventually leading to galling, and small slivers can be left in the die as bits and pieces of the
burr break off. Die polishing and cleaning then become expensive maintenance costs.

• It reduces wall-thickening problems —the flange is the thicker part of the cup that stays under the blankholder.

Why produce a flangeless cup in the first draw operation?

1 of 3 9/18/2019, 5:05 PM
Articles - Deep Drawing from A to Z | MetalForming Magazine https://www.metalformingmagazine.com/magazine/article/?/2008/7/1/D...

• Once the critical punch load is passed as material flows toward the die radius, the amount of blank-edge movement
becomes irrelevant. A general rule: Make the diameter of the initial blank edge as small as possible since forming
severity is not increased. This is accomplished by removing the entire flange.

• Due to the design of redraw dies, a flange can be placed on a flangeless cup by controlling redraw-punch travel.
The flange is created under the blankholder as shown in Fig. 7.

• If a flange has been left on the cup in the first draw operation, it is not practical to
remove the flange or reduce its diameter in a redraw operation. The redraw-
blankholder design will not prevent wrinkling if the flange is placed in compression.
This also presents two other disadvantages: Leaving a flange in the draw
operation creates an excessive amount of trim material, and lines or ridges will be
left in the flange resulting from attempts to flatten or straighten the die radius from
the first draw.

• Drawing a flangeless cup at each draw greatly simplifies cup removal by allowing
the cup to be drawn straight through the die ring and allowing it to exit the bottom
die by gravity, much like a pierce slug is forced through a die cavity and ejected out
the bottom.

Need t o E ase M ateri al F lo w

Redrawing also can create stepped cups by redrawing only a partial depth of the
cup. Ironing is another option for extending the height of a cup without changing
the diameter. Here the cup is redrawn through successive dies with increasing Fig. 7
negative clearance between punch and die diameters. The wall of the cup thins as material extrudes back up the cup
wall.

<< Previous Page Page 2 of 4 Next Page >>

1:2:3:4

READER COMMENTS

Posted by: Jesse Powers on 1/3/2017 1:36:43 PM

In Figure 4, the trailing zeroes on the vertical axis should be "t" (matching the vertical axis in
Figure 5). This would generally agree with other articles.

POST A COMMENT
* Indicates field is required.

YOUR COMMENTS * (You may use html to format)

YOUR NAME * EMAIL * WEBSITE

> Submit

PMA Services, Inc. Home :: Contact :: Sitemap :: Advertise The official publication of
6363 Oak Tree Blvd.,
Independence, Ohio 44131-2500
P: 216-901-8800

2 of 3 9/18/2019, 5:05 PM
Articles - Deep Drawing from A to Z | MetalForming Magazine https://www.metalformingmagazine.com/magazine/article/?/2008/7/1/D...

F: 216-901-9669 © 2019 Precision Metalforming Association. Terms and Conditions Precision Metalforming Association
> Send feedback

3 of 3 9/18/2019, 5:05 PM