DEEP DRAWING

 INTRODUCTION
Process definition:
 Deep drawing is a sheet metal forming process in which a sheet metal
blank is radially drawn into a forming die by the mechanical action of a
punch. It is thus a shape transformation process with material retention.
The process is considered "deep" drawing when the depth of
the drawn part exceeds its diameter.
 The deep drawing process is often a combination of stretch forming and
deep drawing. At the beginning of the forming process, when the punch
moves downwards and form out the bottom, a general stretch forming
process results. When the bottom is formed, the deep drawing process
follows, characterized by transfer of the drawing force from the punch
through the cup wall into the flange. Within the flange results the main
forming process with radial and tangential compression load.
 Deep drawing processes are divided into three types:
 Deep drawing with tools
 Deep drawing with active means
 Deep drawing with active energy
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 In the automotive industry, deep drawing is usually carried out using rigid
tools.

Illustration of the deep drawing process

 The figure illustrates the deep drawing process. The rigid tools consist of a
punch, die and binder. In deep drawing, the plate holder closes after the
metal sheet blank has been inserted.
 Next the sheet is clamped between the die and the binder. This process
slows down the flow of the sheet while it is being drawn and thereby
prevents wrinkles from forming under the binder. The punch stretches the
sheet over the die radius and forms it in the die. The amount of punch force
necessary for forming is thereby continually increased up to the lower dead
center of the punch.
 Whereas in pure deep drawing there is no reduction of sheet metal
thickness, forming is achieved in stretch forming purely as a result of a
decrease in sheet metal thickness. Stretch forming is extensively used for
the forming of only slightly curved parts with low depth of draw (e.g. roofs,
doors).
 When drawing complex car body parts in practice, there is usually a
combination of stretch and deep drawing involved. It is necessary that the
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sheet metal is stretched as well as possible without reaching the material’s
limits (e.g. splits, wrinkles).
 There are approximately 300 to 400 sheet metal parts which fit together to
form the body of a car. In order to manufacture high quality sheet metal
parts optimally for their particular use, specialized software simulates the
complete deep drawing process.

 HISTORY OF DEEP DRAWING

 Like many other advancements in technology the deep draw process began
simply enough, as the brain-child of one man who needed a better method
of producing his products. 
 It was the mid 1800’s, and the American industrial boom had just begun. In
the city of Waterbury, Connecticut, a local man well known and respected
for his mechanical skills named Eli Manville opened the Eli Manville
Company. Along with his brother Frank, Eli used his knowledge of
machinery to invent several new processes that would become pivotal in
the industrial race against England. Machines such as the “Four Slide”, and
the “Hendey Planer and Shaper” were two of his designs from this period. 
 Due to the increasingly popular use of gas lighting, brass fixtures were in
high demand. Following this industrial trend, the Eli Manville Company
specialized in the creation of a wide variety of brass products such as tubes
and lamps, as well as many other brass products. 
 In the later part of 1880, Eli Manville began production of small brass
eyelets to be used in such products as boots, canvasses, and corsets. He
soon realized that the current technology of producing eyelets was simply
too small and cumbersome to be competitive in the marketplace. To
address this, he invented what is generally accepted to be the very first
transfer press, which became synonymous with the term “eyelet machine”. 
 The transfer press opened up entirely new and unexplored possibilities in
manufacturing. As new tooling and materials were developed the eyelet
machine became more and more capable, producing a wide array of
products at previously unachievable speeds and with a quality and accuracy
that the industry had never thought possible.
 Years later, the Eli Manville Company was sold by Eli’s son, Bob. The new
company, the Waterbury Ferrell Company, kept many of the traditions alive
and well, including the transfer press. Over the years the eyelet process was
refined and developed, finally becoming what we now know today as the
deep drawing process.
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EYELET
 PRINCIPLE OF DEEP DRAWING
 A flat blank of sheet metal is formed into a cylindrical cup by forcing a
punch against the centre portion of a blank that rests on the die ring.
The blank may be circular or rectangular, or of a more complex outline.
Blank holder is loaded by a blank holder force, which is necessary to
prevent wrinkling and to control the material flow into the die cavity
simultaneously transferring the specific shape of the punch and the die
to the blank. The material is drawn out of the blank holder-die region
during the forming stage and the material is subjected to compressive
and tensile stresses in this portion.

 APPLICATIONS
 DEEP DRAWING
 The deep draw process can be used for a variety of applications across a
range of manufacturing industries, each offering our customers many
benefits over other fabrication methods.  The deep draw process holds
out cost savings in less material consumption, reduced fabrication costs
to arrive at a finished part, and less dimensional variability for the
millions of parts we produce for our customers each year. 

 Deep Draw Appliance Controls Components

 Deep draw stamping control components serve as precision
nozzles, sensor housings, and thermostatic applications. Designed for
high-heat and high-pressure environments and for corrosion resistance,
300 series stainless steel is frequently the material of choice for deep
draw forming.

 Deep Draw Bearings Components

 High carbon steels and precoated steels are the primary materials used
in deep draw stamping for cups and housings for needle roller bearing
applications. Very close tolerances are held to maintain high
performance and minimal wear. Precise surface finishes, another
essential tolerance, are rendered through the deep draw forming
process.

 Deep Draw Sealing Technology Components

 Deep draw metal inserts provide formed shapes to facilitate the molding
process, eliminating machining as a secondary operation off the transfer
press. Deep draw sealing components require heat treatment for
hardness, special lubricants for the transfer press, and precision
cleaning and coatings to ensure the bonding process. All these value-
added features are provided through PMP’s supply chain.

 Deep Draw Medical Device Components

 Prospect Machine Products has extensive experience working to the
standards of the medical device industry. The deep draw components
we produce are from 300 series stainless steel, as well as titanium 1, 2
and 3. PMP has worked extensively to develop a supply chain for deep
 DEEP DRAWING
draw precision cleaning and packaging to meet the rigorous standards
of the industry.

 Deep Draw  Components for Fluid and Air Control

Valves

 For pharmaceutical, food processing, and rugged industrial

environments. Materials include copper and stainless steels. Processes
include precision cleaning and specialty coatings. Learn about our deep
draw components for fluid and air control valves.

 Deep Draw Aerospace Defense Components

 Deep Draw closed-end containers, sleeves, and housings in aluminum,
stainless, and copper. Learn more about our deep draw components for
Aerospace.

 Deep Draw Automotive Components

 Deep draw stampings for automotive components span a range of
performance applications across the spectrum of car makes and models.
Multiple deep draw forms are essential in suspension, fuel control,
thermal management systems, and electronic controls throughout the
vehicle.

 PROCESS REQUIREMENT
 DEEP DRAWING

 DEEP DROWING PROCESS NEED SOME SETUP AS SHOWN IN FIGURE GIVEN

ABOVE AND SOME SPECIAL MECHANISM TO PROVIDE FORCE TO THR
PUNCH LIKE RAM ETC.

 FORCE REQUIREMENT IN THE PROCESS:

 The deep drawing process involves five stages as discussed earlier: bending,
straightening, friction, compression, and tension. Thus, different parts of
the blank are subjected to different stages of stress, as shown in Fig.

 Therefore, the deformation is not even throughout of the blank. Due to the
biaxial compressive stresses, the flange gets thicker while, the vertical wall
gets thinner, due to the uniaxial tension.
 The maximum thinning is occurring at the lowest part of the vertical wall
adjacent to the bottom of the cup. Because of this uniaxial tension thinning,
failure is expected at the location of maximum thinning.
 DEEP DRAWING

 Requirement of Stock Material in Deep Drawing:

 The basis for the blank development calculation, the rule follows, that the
volume of the metal is constant. In other worlds, the surface area of the
final product is equal to the surface area of the original blank. Let us
consider an example, as shown in Fig. 6.44. The surface area of the cup is
the bottom surface area plus the wall surface area.

∴ According to the rule.

Surface area of the blank = Surface area of the cup

Hence, the diameter of the blank (D) can be obtained, by above formula.

 AFECTING PARAMETER AND

THEIR EFFECT :

 Variables affecting Deep Drawing:

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 The effects of different variables, on the deep drawing process are discussed
below:

1. Bank Holder:
In the deep Drawing process, if

Where, Do  = Blank diameter

d = Punch diameter

t = Thickness of sheet-metal.

 The annular flange will buckle and crimple. This defect is known as
wrinkling. The way to eliminate wrinkling or buckling of thin blank,
is to support it over its entire area. This is achieved by sandwiching
the blank between the upper surface of the die steel and the lower
surface of an annular ring. The annular ring is referred as blank
holder that exerts pressure upon the blank.
 On the other hand, the use of blank holder increases the frictional
resistance and hence increases the force requirement for operation.
To compensate this, dubrication like soap solution, mineral oil,
waxes are applied to both surfaces of the blank. Usually, the blank-
holder force is taken as 1/3 of the drawing force, i.e.

Where, Fbf  = Banking force required

FDF  = Drawing force
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2. Die Corner Radius:

 DEEP DRAWING
 The die corner radius must be optimum. A small die corner radius
would increase the bending and straightening forces. Thus,
increasing the drawing force and final output would not be
satisfactory.

3. Geometry of the Blank:

 The geometry of the blank has a marked effect on the process and
final product. The way of expressing the geometry is the number
indicating the thickness as a percentage of the diameter i.e.
 Number representing blank geometry = t/D × 100
 For smaller value of number (e.g., 0.5), excessive wrinkling should
be expected, unless a blank holder is used. On the other hand, for
higher values of the number (e.g., 3), no wrinkling occurs, and
hence, no blank holder is required.

4. Drawing Ratio:
 An another important variable is the drawing ratio, which can be
defined as

Where, R = Drawing Ratio

D = Diameter of the blank

d = Diameter of the punch

For successful drawing operation, its value must be less than two.

5. Percentage Reduction:
The percentage reduction is given by2
 DEEP DRAWING

Where, r = Percentage reduction.

D = Diameter of the blan

d = Diameter of the punch.

 For sound product without tearing, the value of r must be less than
50 percent. When the final product is long and need to increase the
percentage reduction beyond 50 percent, an intermediate cup must
be produced first, as shown in Fig. 6.42.

 The intermediate cup must have percentage reduction below 50

percent. The value for percentage reduction usually taken as 30
percent for first redraw, 20 percent for second and 10 percent for third
redraw. The product should be annealed after every two redrawing
operations, in order to eliminate the work hardening and thus avoid
any cracking of the product.
 DEEP DRAWING

 Requirement of Stock Material in Deep Drawing:

The basis for the blank development calculation, the rule follows, that the
volume of the metal is constant. In other worlds, the surface area of the
final product is equal to the surface area of the original blank. Let us
consider an example, as shown in Fig. 6.44. The surface area of the cup is
the bottom surface area plus the wall surface area.

∴ According to the rule.

Surface area of the blank = Surface area of the cup

 DEEP DRAWING

Hence, the diameter of the blank (D) can be obtained, by above formula.

 Drawing of Stepped, Conical and Domed Cups:

The stepped cups are produced in two or more stages by deep drawing
operation. In first stage, a cup is drawn to have the large diameter. In
second stage, a redrawing operation is performed on only the lower
portion of the cup.

In the same way, conical and tapered cups cannot be drawn directly. First,
they have to be made into stepped cups, which are then smoothed and
stretched out to the required tagered cups. The deep drawings of different
cups are shown in Fig. 6.45.

The following is a brief description of commonly found deffects:

1. Wrinkling or Puckering:
The wrinkling defects are a kind of buckling of the undrawn part of the blank. This
defect is caused by the excessive compressive stresses if the slenderness ratio is
higher than a certain value. This may occur in the vertical walls, as shown in Fig.
6.46 (a) and (h). If this defect occurs on the punch nose when drawing a domed
cup, it is known as Puckering.

2. Tearing:
 DEEP DRAWING
The tearing defect usually occurs in the radius connecting the cup bottom and the
wall. This defect is caused by high tensile stresses due to the obstruction of the
metal flow in the flange.

3. Earing:
As its name indicates, the formation of ears at the free edges of a deep-drawn
cylindrical cup is known as earing defect, Fig. 6.46 (c). This defect is caused by the
anisotropy of the sheet metal.

4. Surface Marks:
These defects include, draw marks, burnishing, step rings, etc. This defect is
caused by improper punch-die clearance and poor lubrication.

5. Surface Irregularities:
This defect is caused by non-uniform yielding of metal due to non-uniform forces.

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