Manufacturing Technology

Assignment 1 about

Deep drawing

Wire drawing

12. Illustrate the followings:

 Deep drawing
 HDD

Deep drawing
Is the forming of smooth (blanks into hollow
parts it is a process which involves forming by
tensile and compressive forces.

Procedure
1. The blank is placed on the die surface
and the blank holder pressure is applied.

2. The punch moves axially to draw the

part.

3. The punch force is transmitted through

the part wall to the flange which is the
deformation zone.

4. The blank holder prevents wrinkling of

the flange.

Hydro mechanical deep drawing (HDD)

The circular blank to be formed (first draw) is pressed directly onto the downward-moving drawing die by a
pressurized liquid pad giving it the exact shape of the drawing punch.
 Suitable for Aluminum
Deep drawing, it is possible to form flat sheet blanks or preformed sheets to hollow bodies of various complex
geometries. With this process it is also possible to produce shapes with tapered bodies in a single step, which
would otherwise require several drawing steps in a conventional deep drawing process.
 advantages
Better form and dimensional accuracy
A higher drawing ratio
Reduced residual stresses and the production of parts with undamaged surfaces
13. A circular cup is to be drawn from a steel blank 1 mm thick. The outside diameter of the cup is 71 mm. The cup
height is 90 mm. Find the blank diameter required to draw the cup.

14. Explain with sketches the difference between direct and reverse redrawing then mention the advantages of
reverse redrawing.

Direct and reverse redrawing

In direct redrawing drawn cap is same face

such as first deep drawing.

In reverse redrawing cap is reverse face

have first deep drawing.

Reverse redrawing

1. The main advantage of reverse redrawing is the

reduced amount of bending over the die curvature.

2. Both first draw and reverse redrawing are carried

out together in one working step.

3. Stepped tool one transport stroke is eliminated.

15. List with the aid of sketches the defects of deep drawing parts and mention the reasons of each of them.

1. Wrinkling in the flange occurs due to compressive buckling in the circumferential

direction (blank holding force should be sufficient to prevent buckling from occurring).

2. Wrinkling in the wall takes place when a wrinkled flange is drawn into the cup or if
the clearance is very large, resulting in a large (unsuspended) region.

3. Tearing occurs because of high tensile stresses that cause thinning and failure of the
metal in the cup wall Tearing can also occur in a drawing process if the die has a sharp
corner radius.

4. Earring occurs when the material is anisotropic, has varying Properties in different
directions.

5. Surface scratches can be seen on the drawn part if the punch and die are not smooth
or if the lubrication of the process is poor.

16. List the possible reasons for the cup wrinkling during deep drawing.

1. Planking holder pressure not enough.

2. Die radius edge to large.

3. Punch radius edge to large.

4. Sheet thickness less than 1 % diameter cup.

17. A circular cup is to be drawn from a steel blank 1mm thick. The outside diameter of the cup is 61. The
cup height is 80 mm.
Find out:
I. The blank diameter required to draw the cup,
II. The number of redraws needed, if the max ratio for drawing is 2 and that for redrawing is 1.25

* State some of the possible reasons for cup fracture in deep drawing.

1. Die edge radius to small rd<.

2. Punch radius to small rp<.

3. Blank holder pressure to large.

4. Drawing ratio greater than maximum ratio.

5. Strain rate is to large makes punch down speed.

6. Punch have scrape (‫)تاكل‬.

7. Non concentric axis between punch and die.

8. Use bad lubrical.

9. Defect for sheet material.

10. Non homogenous sheet thickness.

18. Sketch the die used for wire drawing showing its main parts then mention the effect of the die angle on
friction force and internal shearing force and explain how you can get the optimum die angle.

•The entry region: is generally a bell shaped mouth that

does not contact the work piece.

Its function is to contain and push the lubricant into the

die and prevent wearing of work and die surfaces

•The approach region is where the drawing operation

occurs. It is cone shaped with an angle (half angle)
normally ranging from 6 to 20

•The bearing surface or land, determines the size of the

final drawn work piece

•Finally, the back relief is the exit zone. It is provided

with a back relief angle (half angle) of about 25 30 °°.

19. A steel wire 5.8 mm diameter is drawn to 4.6 mm using a die whose angle is 5º. The coefficient of
friction at the die working surface is 0.1. Calculate the percentage reduction in the drawing force if a die
with an optimum angle was used.
20. A steel wire 6.8 mm diameter is drawn to 5.9 mm using a die whose angle is 8º. The coefficient of
friction at the die working surface is 0.1. The wire entering the die has been subjected to a logarithmic
strain = 0.15. The flow curve is given by: σf = 670 φ0.25 [N/mm2], Find out:

The total drawing force. If the ultimate tensile strength of the sheet material is σult. = 420 MPa, is the
operation successful?

I. How much of this force is required to overcome friction force?

II. How much of this force is required to overcome internal shearing force?

III. What is the optimum die angle for the given working conditions?

IV. Calculate the percentage reduction in the drawing force if a die with an optimum angle was used.

V. Compare friction force and internal shearing force when the die angle is 8º and when it is optimum.
 21. Illustrate the followings:

I. Wire drawing

While wire drawing is meant for small diameter stock. Wire sizes of the order of 0.03 mm are produced in wire
drawing.
wire is drawn from coils consisting of several hundred meters of wire and is drawn through a series of dies The
number of dies varies between 4 and 12 This is termed as continuous drawing because of the long production runs
that are achieved with the wire coils The segments can be butt welded to the next to make the operation truly
continuous.

II. Bar drawing

Bar drawing is meant for large diameter bar and rod.

Operating stages: Bar drawing is generally done as a single stage operation, in which stock is pulled through one
die opening. The inlet bars are straight and not in the form of coil, which limits the length of the work that can be
drawn. This necessitates a batch type operation.

22. List with sketches the different types of tube drawing and mention the application of each method.

Drawing without a mandrel (tube sinking) The tube is pulled through the
drawing die hole with no support from inside In this process, only the external
diameter measurements are precise the wall thickness and internal diameter
deviate more This process, known as tube sinking, is only applied to tubes
with smaller internal diameters

Using a fixed mandrel In this case, a mandrel is attached to a long support bar to
control the inside diameter and wall thickness during the operation the length of
the support bar restricts the length of the tube that can be drawn.

Using a floating plug: As the name suggests the mandrel floats inside the tube
and its shape is designed so that it finds a suitable position in the reduction
zone of the die. There is no length restriction in this as seen with the fixed
mandrel.