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Sheet metal Drawing (deep drawing)

Deep drawing is used to make

cup-shaped, box-shaped, or other
complex-curved, hollow-shaped
parts
 Sheet metal Drawing (deep drawing)

How to accomplished of deep drawing

Sheet metal blank is positioned over die
cavity and then punch pushes metal into
opening die
FIGURE 20.20 Stages in deformation of the work in deep drawing: (1) punch makes initial contact with work, (2) bending,
(3) straightening, (4) friction and compression, and (5) final cup shape showing effects of thinning in the cup walls.
Symbols: v = motion of punch, F = punch force, Fh = blankholder force.
 Clearance in Drawing

▪ Sides of punch and die separated

by a clearance c given by:
c = 1.1 t
where t = stock thickness
▪ clearance is about 10% greater
than stock thickness
Clearance between punch and die in
deep drawing
 Tests of Drawing Feasibility
▪ Drawing ratio
▪ Reduction
▪ Thickness-to-diameter ratio
 Drawing Ratio DR

Most easily defined for cylindrical

shape:
Db
DR =
Dp

where Db = blank diameter; and Dp

= punch diameter
▪ Indicates severity of a given
drawing operation
▪ Upper limit: DR  2.0
 Reduction r

▪ Defined for cylindrical shape:

Db − Dp
r=
Db

▪ Value of r should be less than 0.50

Thickness-to-Diameter Ratio t/Db
Thickness of starting blank divided by blank
diameter
▪ Desirable for t/Db ratio to be greater than 1%
▪ As t/Db decreases, tendency for wrinkling
increases
 Blank Size Determination
▪ For final dimensions of drawn shape to be
correct, starting blank diameter Db must be
right
▪ Solve for Db by setting starting sheet metal
blank volume = final product volume
▪ To facilitate calculation, assume negligible
thinning of part wall
Calculation of blank diameter
Calculation of blank diameter
Calculation of blank diameter
Blank diameter of various shaped
Blank diameter of various shaped
 State of stresses in deep drawing

FIGURE 7.50 Deformation of elements in (a) the flange and (b) the cup wall in
deep drawing of a cylindrical cup.
 Example

A drawing operation is used to form a cylindrical cup

with inside diameter 75 mm and height 50mm. The
starting blank size 138mmand the stock thickness
2.4mm. Based on these data, is the operation
feasible?
 Forces

The drawing force required to perform a given operation can be estimated

roughly by the formula:

where F drawing force, N (lb); t original blank thickness, mm (in); TS tensile

strength, MPa (lb/in2); and Db and Dp are the starting blank diameter and punch
diameter, respectively, mm (in). The constant 0.7 is a correction factor to account
for friction. Eq. (20.12) estimates the maximum force in the operation. The
drawing force varies throughout the downward movement of the punch, usually
reaching its maximum value at about one-third the length of the punch stroke.
Punch load - displacement curve in D.D
 The holding force

The holding force is an important factor in a drawing

operation. As a rough approximation, the holding
pressure can be set at a value =0.015 of the yield
strength of the sheet metal [8]. This value is then
multiplied by that portion of the starting area of the
blank that is to be held by the blankholder. In equation
form,
 Example

For the drawing operation of Example 20.3, determine (a)

drawing force and (b) holding force, given that the tensile
strength of the sheet metal (low-carbon steel) =300 MPa
and yield strength = 175 MPa. The die corner radius = 6
mm.
 Shapes other than Cylindrical Cups

▪ Square or rectangular boxes,

▪ Stepped cups
▪ Cones
▪ Cups with spherical rather than flat bases
▪ Irregular curved forms (as in automobile
body panels)
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