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Deep Drawing Process
Deep Drawing Process
Lecture#4:
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.
https://www.youtube.com/watch?v=Ag53ek5NLw0
𝐷𝑜
▪ The drawing ratio is calculated as:
𝐷𝑝
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
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.
Automobile parts
Rocket nose cone
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.
Shear spinning
▪ It is the spinning process with simultaneous thinning of the sheet metal during the process.
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
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.
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
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
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
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
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
S. Mukhopadhyay Metal forming ME361A
Mechanical analysis
outside
inside
∧
Directional earing
The height of the drawn cups have peaks and valleys called earing. Earing results from planar anisotropy.
Miss strike
Initial misplacement of the stock with respect to the punch and/or die results in unsymmetrical flanges,
knows as miss strike .
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.