Drawing process‫عملية السحب‬

 Drawing is the process of making cups, shells and similar articles from metal
blanks .
 The setup is similar to that used in blanking except that the punch and die are
provided with the necessary rounding at the corners to allow for the smooth
flow of metal during drawing.

Figure : Drawing operation

Steps of Drawing process
 The blank is first kept on the die block.
 The punch slowly descends on the blank and forces it to take the cup shape
formed by the end of the punch.
 When the cup reaches the counter bored portion of the die, the top edge of
the cup formed around the punch expands slightly due to the spring back.

Figure : Drawing operation

 When the punch moves in the return stroke, the cup would be stripped by
this counter bored portion.
 This description is true in the case of shallow drawing operation only.
 Shallow drawing is defined as where the cup height is less than half the
diameter.

Figure : Drawing operation

 For drawing deeper cups it is necessary to make specific provisions ‫اجراءات محددة‬
to confine ‫ تحدد وتحجز‬the metal in order to prevent excess wrinkling of the
edges.
 For this purpose, a blank holder is normally provided(used) on all deep drawing
dies as shown in Figure.

Figure :Blank holding in deep drawing

 A more common usage is the spring loaded pressure pad.
 The spring loaded pressure pad which moves with the punch, maintains a
more uniform pressure on the blank throughout the drawing operation..

Figure :Draw die with spring load pressure pad

Defects in deep drawing are
1- Shearing ‫ القص‬:- It is the shearing failure of blank material at corners of die and at
corners of punch. It occurs when the stresses in blank material overcomes (exceeds)
ultimate stresses.
2-Wrinkling ‫ تجع>د وتقلص‬When the blank holding force is less than optimum holding force
then it will results in wrinkling of collar of product. It is a result of non-uniform flow of
material into the die cavity

Figure: Defects in deep drawing. a- Wrinkling in the flange, b- Wrinkling in the

wall,
3-Earing :
Earing is a result of non-uniform flow of material into the die cavity when the blank
holding force is less than optimum holding force resulting in occurrence of a wavy edge
at the top.
It is occurs due to the presence of gap between blank and blank holder.
If the holding force is optimum then earing defect will not occur.

Figure: Defects in deep drawing. a- Wrinkling in the flange, b- Wrinkling in the

wall,
 Flow of metal in deep drawing process

 To understand the problem of

wrinkling, consider the drawing of a

cup as shown in Figure.

 The blank has been divided into sections

1 to 4.

 The example is presented for a circular

cup since these are more generally used.

 It is also possible to draw other sections,

such as rectangle, but that would be

much more difficult. Figure: Flow of metal in deep drawing

 The first contact made by the punch with the blank is over the portion marked 1 which
forms the bottom of the cup. In this portion, there is no deformation of the blank.
 As the punch further moves down, the metal shown in the ring 2 of the blank gets bent
by the punch over the die radius.

Figure: Flow of metal in deep drawing

 Upon further movement of the punch, the bent blank over the die radius gets
straightened and the next ring (Ring 3) of the metal is bent over the die radius.
 Since the metal present in each of the rings is distributed over a circle of larger
diameter than that of the cup, the material needs to be moved radially for the
drawing action to occur .

Figure: Flow of metal in deep drawing

 While the material is flowing radially, the outer edge gets thicker or
wrinkles are formed on the outer edges, if there is no restraining
force applied on the blank.

Figure: Flow of metal in deep drawing

 The restraining force ‫دة‬/‫ة والمقي‬/‫وة المعيق‬/‫ الق‬applied on the blank by the blank
holder stops the blank from increasing in thickness beyond a limit but
makes it to flow radially outward.

Figure: Flow of metal in deep drawing

 The limiting thickness is controlled by the gap between the rigid blank holder and
the die or by the spring pressure in the case of a spring loaded blank holder.
 Too high a blank holder pressure increases the friction and subsequently the
drawing load.
 A lubricant is normally applied over the face of the blank to reduce this friction.

Figure: Flow of metal in deep drawing

 Shallow drawing is a relatively simple drawing operation .
 deep drawing is a drawing operation when cup height is more than half the diameter of cup
 (height of cup > half diameter of cup ) or (h/d )> 0.5 .
 Ductile materials are easier to be drawn into deeper cups.

 In deep drawing, because of the radial flow of material, the side walls increase in
thickness as the height is increased, as shown in Figure.
 There would be a slight thinning of metal at the bottom corners.
 For applications requiring uniform side walls, an operation called ironing is carried
out on drawn cups.

Figure: Side wall taper in deep drawing

Ironing
 Ironing is the operation of thinning the side walls and increasing the height.
 The die and punch set used is similar to that of drawing operation except that the
clearance between the die and punch is smaller than that used in the drawing
operation.
 The material gets compressed between punch and die which reduces the thickness
and increases the height, and thus is a severe operation.
 The wall thicknesses can be reduced to as much as 50 % in a single ironing operation

Fig. Ironing operation

The advantages of deep drawing process are as follows
 It is quick operation.
 Skilled operators are not required.
 It is simple process.
 It requires less setup cost.

The applications of deep drawing process are as follows

 Kitchen utensils ‫اوانى المطبخ‬
 Cylindrical & hemispherical shaped containers.
 Fire extinguishers cylinders ‫طفايات الحريق‬.
 Questions on Drawing process

Difference between Shallow drawing and deep drawing

If the ratio of height to diameter of product is greater than 0.5 then this drawing
operation is known as deep drawing (height of cup > half diameter of cup ) or
(h/d )> 0.5
and If the ratio of height to diameter of product is less than 0.5 then this operation
is known as shallow drawing. (height of cup < half diameter of cup ) or (h/d ) <
0.5
What is deep drawing used to make?
Deep drawing is used for making Kitchen utensils, Cylindrical & hemispherical
shaped containers.
How do you distinguish between shallow and deep drawing?
If the ratio of height to diameter of product is greater than 0.5 then this drawing
operation is known as deep drawing and If the ratio of height to diameter of
product is less than 0.5 then this operation is known as shallow drawing.
What is clearance in deep drawing?
Clearance is the distance between the die and punch .
it should be optimum to avoid shear failure in blank.
The clearance is 10% more than thickness of sheet metal. C=1.1t
How do you prevent wrinkles in a deep drawing?
To prevent wrinkles defect in deep drawing, the holding pressure onto the blank should be
optimum.
What is the h to d ratio in deep drawing process?
it is the height (h) to Diameter (d) ratio of the product.
If the ratio of height to diameter of product is greater than 0.5 then this drawing operation is
known as deep drawing. (height of cup > half diameter of cup ) or (h/d )> 0.5
What is the cause of earing defect in deep drawing?
A major defect which affects the quality of the deep drawn cups is the occurrence of a wavy
edge at the top, commonly referred to as the earing defect. Earing is a result of non-uniform
flow of material into the die cavity
It is occurs due to the presence of gap between blank and blank holder. If the holding
pressure is optimum then earing defect will not occur.
What is the importance of blank holding force in deep drawing
operation?
The blank holding force is required to hold blank onto the die surface.
If the holding force less than the optimum holding force then it results
in wrinkling and earing defects.
If the blank holding force is more than required limit then it may
results in shear failure at the corners.