Sheet Metal Forming

Cup Drawing
OUT LINE
 Mechanics of Drawing
 Introduction

 Engineering Analysis of Drawing

 Defects in Drawing
Basic Principles of Drawing

Drawing is a sheet metal forming operation used to

make cup-shaped, box-shaped, or other complex-
curved, hollow-shaped parts. It is performed by
placing a piece of sheet metal over a die cavity
and then pushing the sheet into the opening with a
punch
 Mechanics of Drawing
A blank of diameter Db is drawn into the die by means of a punch of
diameter Dp. The punch and die have corner radii Rp and Rd,
respectively. The sides of the die and punch are separated by a
clearance, c, which is about 10% greater than the sheet thickness. The
punch applies a downward force, F, to deform the metal while the
downward holding force, Fh, is applied by the blank holder.
As the punch proceeds towards its final position, the work piece
experiences a complex sequence of stresses and strains as it is formed
into its final shape.
Mechanics of Drawing
 In step 1, the blank
holder force, Fh, is applied
and the punch begins to
move towards the sheet
material
Mechanics of Drawing
 In step 2
The sheet material is subjected
to a bending operation. The
sheet is bent over the corner
of the punch and the corner
of the die.

as the punch continues moving

down, a straightening action
occurs in the metal that was
previously bent over the die
radius.
Mechanics of Drawing
 In step 3 as the punch
continues moving down, a
straightening action
occurs in the metal that
was previously bent over
the die radius. Metal
from the outside edge of
the blank is drawn into the
die opening to form the
cylinder wall.
Mechanics of Drawing

 In step 4,
friction between the sheet
material and surfaces of the
blank holder and die must be
overcome in order for the
material to be drawn.
Compression is also
occurring at the outer edge
of the blank. As the metal is
being drawn in toward the
center, the outer perimeter
becomes smaller. The
volume of metal remains
constant, however, and thus
the metal is squeezed and
becomes thicker in the flange
area.
Mechanics of Drawing
 Step 5 The downward
motion of the punch
results in a continuation
of the metal flow caused
by drawing and
compression. Some
thinning at the cylinder
walls occurs as well.
shows the completed
drawing process.
Engineering Analysis of Drawing
The drawing ratio, DR, gives an indication of the
severity of the drawing operation: the higher the
ratio, the greater the severity. The drawing ratio is
defined as:
Db
Should be less then 2.0 DR 
Dp
Where, Db = blank diameter and Dp = punch diameter.
This value is dependant upon punch and die corner
radii, friction conditions, draw depth, and material
properties of the sheet metal.
Engineering Analysis of Drawing
The drawing force required to
perform a drawing operation
can be roughly estimated by
the following formula:

 Db 
F  D p t TS   0.7 
D 
 p 
Where
F = Drawing force
t = Original blank thickness
TS = Tensile strength
Db = Blank diameter
Dp = Punch diameter
 Engineering Analysis of Drawing
The blank holder force required for a
drawing operation to prevent
defects is approximated by the
following formula:


Fh  0.015Y D  D p  2.2t  2Rd 
2
b
2

Where
Fh = Blank holder force
Y = Yield strength •Fh which is
Db = Blank diameter normally 1/3F
Dp = Punch diameter
Rd = Die corner radius
 Defects in Drawing
A number of defects in drawing can occur, which include:

(a) Wrinkling in the flange occurs due to compressive buckling because of a

small blank holder force.
(b) Wrinkling in the wall takes place when a wrinkled flange is drawn into the
cup.
(c) 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.
(d) Earing occurs when the material is anisotropic, i.e. has varying properties in
different directions.
(e) 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.
Thank u