Deep drawing

Introduction

Definition 1 drawing punch

2 blank holder
Deep drawing is the 3 drawing ring
forming of sheet blanks 4 Container
into hollow parts. 5 base plate
6 ejector
Products
 Deformation - stress

Role of tangential stress in wrinkling

 Deformation - stress

Complex inhomogeneous stress and strain state

 Role of blank holder

if D/s < 20 (thick sheet), no blankholder needed

Too low blank holder pressure

↓
wrinkling

Too high blank holder pressure  crack

 Defects

Wrinkling Wall wrinkling Crack Earing

Deep drawing without blankholder
with tractrix curved die
 Deep drawing with heated die

heating

cooling

For high strength and for materials with low deep drawability
Multistep deep drawing – second step
Multistep deep drawing – reverse redrawing

punch
punch
blankholder
blankholder

cup
Drawing ring
Drawing ring

Partially Partially
redrawn cup redrawn cup

11
 Blank geometry – axisymmetric part

Assuming constant surface area:

D 2 d m2 
A   d m h  h
4 4
D  d m2  4d m h  h
dm
h’

If the workpiece consist of simple shapes

( A1,A2.....An)
db
H h
D 2 n
4 n
s A   Ai , D   Ai
4 i 1  i 1
s
h/d=0,5..4 mm, h=20..300 mm,
D h’=2-12 mm
 Technology planning
Due to the material and geometric limit, not any geometry can be done
in one step; The drawn cup can be formed further in other deep drawing
steps. For each steps a draw ratio mt=dn/dn-1 can be defined: the ratio of
the diameters in the nth and n-1th step.
Its maximal values is material dependent, but m=0.55-0.6 for the first step
(forming a cup from planar blank) and mt=0.75-0.85 for the further drawing
steps.

For cylindrical pieces

1) Assuming that the surface area is constant; the surface area of the final
geometry is calculated.
2) If the material anisotropic, this vales is increased with 5-15% depending
on the anisotropy of the material
3) The blank diameter D is calculated
 Technology planning

Knowing the maximal drawing ratio, the first diameter d1=mD, the further
drawing diameters can be determined d2=mtd1=mtmD, d3=mtd2=mtm2D.

Diameter after n drawing: d n  mtn 1 mD

If D and dn are known, then:

ln d n  ln mD
n 1
ln mt
The values must be rounded up, verify the changes ratios. It is useful to
have continuously increasing ration from the first step.
 Technology planning – blank for complex
geometries

Breakdown of a rectangular hollow Evening out the design of the blank

part into elements of equal area using arcs or straight lines
Technology planning
Related technique - ironing
Die design examples
Die design examples
Hydro mechanical deep drawing