15P602-JIGS FIXTURES AND DIE DESIGN

ASSIGNMENT PRESENTATION - BATCH 6

TOPIC- DESIGN OF DRAWING DIES

GOKUL.K (18P105)
SANJAY.S (18P221)
GOWTHAM.K (19P402)
VIJAY AMIRTHARAJ.M (19P433)
SYED AHAMMED KABEER .A.M (19P434)
DRAWING DIES
• A die used to shape cuplike articles out of sheet metal that is pushed into it by a
punch and prevented from wrinkling by a blank holder which holds the outer
edge of the metal firm

• Drawing dies are typically made of tool steel, tungsten carbide, or diamond, with
tungsten carbide and manufactured diamond being the most common.

• For drawing very fine wire a single crystal diamond die is used.For hot drawing,
cast-steel dies are used. For steel wire drawing, a tungsten carbide die is used.

• The dies are placed in a steel casing, which backs the die and allow for easy die
changes.

• Die angles usually range from 6–15°, and each die has at least 2 different angles:
the entering angle and approach angle.
Carbide Drawing Dies

Carbide drawing dies are use in making wire, pipe (tubing), rods and bars.
The high compressive strength of tungsten carbide allows it to handle extreme
pressure, making it ideal for use in drawing dies.

For this reason, carbide dies are used in the drawing process by all major
manufacturers.

Drawn materials include mild steel, stainless steel and high carbon steel as
well as other steel alloys. Softer materials, like aluminum and copper alloys, are
frequently drawn as well.
Wire Drawing Dies

• The wire drawing process involves drawing wire of a larger diameter

through a die with a smaller diameter bore.

• This reduces the diameter of the wire to produce the desired size and
tolerance of the wire, while the volume remains the same.

• Wires are sized by drawing them through a series of wire drawing dies,
with each successive die having smaller bore diameter than the one
preceding it. The final die in the series forms the wire to its final size.
Tube or Pipe Drawing Dies
• Tube, or pipe, drawing dies can be round, hex or square as well as any custom
shapes desired. The process is similar to the wire drawing process;

• however, a mandrel is used to form the inner dimensions of the tubing. The
mandrel is placed at the throat of the die and used to determine the wall
thickness and inner diameter.

• A properly formed mandrel will provide for a smooth surface on the inside of the
tube or pipe.
Rod and Bar Drawing Dies

• Bars and Rods are drawn in a similar fashion to wire, only they tend
to be much thicker. A wide variety of metals are used for this
purpose, including many steel and copper alloys. A cut-off knife is
used to size the rods and bars to length.

TYPES OF DRAW DIES

• Single action draw dies
• Double action draw dies
SINGLE ACTION DRAW DIES
• The simplest type of draw die is one with a punch and die. Each
component may be designed in one piece without a shoe by
incorporating features for attaching them to the ram and bolster plate
of the press.

SIMPLE TYPE DRAW DIES HEAVY STOCK DRAW DIES

• A simple form of drawing die with a rigid, flat blank-holder for use with .
0897 in. (2.278 mm )
• When the punch comes into contact with the stock, it will be drawn into
the die without allowing wrinkles to form.

• This die is a plain, single-action type

where the punch pushes the metal blank
into the die using a spring-loaded
pressure pad to control the metal flow.
• The cup either drops through the die or
is stripped off the punch by a pressure
pad.
Draw die with spring pressure pad
 DOUBLE ACTION DRAW DIES
• In dies designed for use in a double-actionpress, the blank-holder is fastened to
the outer ram, which descends first and grips the blank.

• Then the punch, which is fastened to the inner ram, descends, forming the part.
• These dies may be a push-through type, or the parts may be ejected from the
die via a knockout attached to the die cushion or by means of a delayed action
kicker.

DOUBLE ACTION DRAW DIE

DESIGN CONSIDERATION FOR DRAW DIES

• Decide the blank holder shape

• Decide for the beads at appropriate places for deeper draws
• For shallow draws provide some locations for trim dies in non working area
• Calculate the draw force required
• Calculate the cushion force required for blank holder as it plays an
important role in flow of material
• Select the suitable press required either mechanical or hydraulic as
specified by the customer
• Select the cushion area in such a way that it balances the blank holder
• Select for clamping slots required from the press layout
• Material for draw punch & die is HcHcr hardened to 56-58 HRC.
• Provide wear plates for draw punch & blank holder sliding at appropriate
position so that it balances
• Provide guide pillars on blank holder & guide bush on draw die. So that
there will be initial alignment between the draw die & blank holder.
• Provide heel guides with wear plates on draw die only if customer insists
or other wise it is not necessary
• Decide for blank holder travel (blank holder surface should be always
above the punch surface by 5-10 mm)
• Provide shoulder bolt at appropriate position & to be fastened to bottom
punch/base plate so that in controls the travel of blank holder.
ELEMENTS OF DRAW DIE
1-Shank
2-Upper shoe
3-Die drawing ring
4-Punch
5-Upper pad
6-Blank holder
7-Guide pin
8-Cushion pin
9-Lower shoe
10-Elastic stop
• Shank- Shank is mounted on upper shoe for mechanical press to connect upper shoe with ram.
• Upper shoe - It is a part of the die, fixed to ram of the press with the help of clamping screw. It moves
along the ram and guided by guide pillar or wear plates mounted on lower shoe.
• Die drawing ring – It is fixed on upper shoe with the help of screw and dowel. It has same shape of
punch maintaining clearance.
• Punch - Punch has same shape of output component required from the die. It is mounted on lower
shoe with help of screw and dowel.
• Upper pad – It is mounted on upper shoe with help of side pin or safety screw or both. It has only one
degree freedom along vertical direction.
• Blank holder – This part of the die is mounted on lower shoe of the die. It has single degree of freedom
in vertical direction.
• Guide pin – It is the guiding component used for the alignment of upper shoe and lower shoe during the
operation. It is also used for the guiding of blank holder in the lower shoe.
• Cushion pin – It is the source of force for the blankholder. The selection of cushion pin is based on
force required for blank-holder, travel of the blank-holder and space available.
• Lower shoe - It is a part of the die, fixed to bolster of the press with the help of clamping screw. Lower
shoe may be made by casting or made up of steel plate based on the requirement of the design.
• Elastic stop – It is a pressure source of upper pad which provides force to hold the sheet metal at
proper location before the start of deformation of sheet metal.
Steps in Drawing die design
1. Corner radius on punch
2. Draw radius on die
3. Clearances
4. Blank size
5. Drawing force
6. Blank holding force
7. Ironing force
8. Percent reduction
9. Air vent
10. Drawing speed
Corner radius on punch
Though there is no set rule for the provision of corner radius on the punch, it is
customary to provide a radius of four to ten times the blank thickness.
Too small a corner radius makes for the excessive thinning and tearing of the
bottom of the cup.
Ideally, the punch radius should be the same as the corner radius of the required
cup, because it takes its form.
For the initial draws, larger punch radii are used and for the final draw use the
requisite radius.
If the requisite radius is less than 4 times the blank thickness, it may be
necessary to obtain it by restriking after the final draw with 4 times the thickness.
Draw radius on die
Since the draw radius on die does not contribute to the cup shape, it can be made as
large as possible.
Higher the radius, higher would be the freedom for the metal to flow.
Too high a radius causes the metal to be released early by the blank holder and thus
lead to edge wrinkling.
Too small a radius causes the thinning and tearing of the side walls of the cups.
draw radius = 4 t normal
= 6 to 8 t (when the blank holder is used )
= 0.8 (D-d) t (where t = blank thickness )
In order to minimise the thinning of the stock, the centre point of the draw radius
should be about 3 mm outside of the previous cup draw.
Also the centre point of the corner radius on punch be slightly inside the shell of the
next draw.
Clearances
Ideally, the clearance between punch and die should be same as the blank
thickness.
But the blank gets thickened towards the edge because of the metal flow and
hence, the actual clearance provided is slightly higher to account for this thickening.
An allowance in the range of 7 to 20% of the blank thickness is provided
depending on the cup material and cup dimensions.
Blank size
It is often difficult to find a blank of the exact size required for making a given
shell, because of thinning and thickening of sheet during drawing.
The calculation could be based on volume, surface area or by layout.
Blank size (cylindrical shells)
where r = corner radius on the
punch, mm
h = height of the shell, mm
d = outer diameter of the shell, mm
D = blank diameter, mm
 Drawing force
The drawing force depends on the cup material, its dimensions and the
configuration. The drawing force for cylindrical shells
Where P = drawing force, N
t = thickness of the blank material, mm
s = yield strength of the metal, MPa
C = constant to cover friction and bending. Its value is between
0.6 and 0.7
Blank holding force
The blank holding pressure required depends on the wrinkling tendency of the
cup, which is very difficult to determine and hence it is obtained more by trial and
error.
The maximum limit is generally to be one third of the drawing force.
Ironing force
In ironing, the objective is only to reduce the wall thickness of the cup, and hence
no blank holding is required because the punch is fitted closely inside the cup.
Neglecting the friction and shape of the die, the ironing force can be estimated
using the following equation.

Where F = ironing force, N

d1 = mean diameter of the shell after ironing
t1 = thickness of shell after ironing
to = thickness of the shell before ironing
Sav = average of tensile strength before and after
ironing
Percent reduction
The drawing operation relies on the ductility of the blank material.
The ductility is affected by the amount of strain a material takes.
But there is a limit to which it can be strained.
The amount of straining or the drawability is represented by the percentage
reduction which is expressed in terms of the diameter of the blank and the shell.
The diameter of the shell to be used is either ID (internal diameter) or OD
(outer diameter).
But it is convenient to use OD since the cup is normally specified by OD.
The percent reduction, P is given by
Air vent
An air vent is normally provided in the punch to reduce the possibility of formation of vacuum in the
cup, when it is stripped from the punch.
For cylindrical shells, one vent located centrally would be enough, where as for other shapes it
may be advantageous to provide two.
Drawing speed
The speed with which the punch moves through the blank during drawing, is termed as the
drawing speed.
This is a very important parameter in drawing because higher speeds are sometimes detrimental.

Particularly harder and less ductile materials are likely to be excessively thinned out due to
excessive drawing speeds.
CASE STUDY
DESIGN OF DRAW DIE FOR CYLINDRICAL CUP FORMATION
Design a draw die to produce cylindrical cup shaped output component from flat
metal sheet as input, by taking inputs from the process engineering department.
Fig shows the input and output part of the die respectively. The input part is
metal sheet of 110mm X 110mm X 0.8mm
Draw tool Output part