4.

Deep Drawing:
The flange is the deformation zone.
d
m
D
0
4.1Definition:
Deep drawing is the forming of smooth (sheet) blanks into hollow parts. It is a
process which involves forming by tensile and compressive forces.
D
The deformation takes place using:
a deep drawing ring, drawing punch and blank holder. In the process,
the punch draws the material through the gap formed by the punch
and the drawing ring, forming it into a cup.
Tooling and workpiece layout during the
deep drawing process:
1 drawing punch,
2 blank holder,
3 drawing ring (drawing die),
4 container,
5 base plate,
6 ejector
1. All of the energy expended is used to deform the material
in the flange. The work against friction and the work to
bend and unbend the material as it flows over the die lip
are neglected in the initial treatment, but will be
accounted for later by an efficiency factor.
2. The material does not strain harden.
3. Flow in the flange is characterized by plane strain,
z
= 0,
so the thickness of the cup wall is the same as the
thickness of the blank.
Main assumptions made for the calculation of the ideal
drawing force:
4.2 Determination of the drawing force:
F
m
f D
d
D
S d F q o t / ln
|
.
|

\
|
=
h
where S is the sheet thickness
o
fm
is the mean flow stress of the material during the drawing
d is the punch diameter
D is the outer diameter of the plank at the present state
q
F
is the forming efficiency,
% 80 ~ % 60
F
q
The the maximum drawing force ( F
D
) can be expressed as:
D
D
0
d
H
h
(1)
(2)
D
1
at fiber (1):
|
.
|

\
|
=
|
.
|

\
|
=
|
|
.
|

\
|
=
D
D
D
D
l
l
0 0
0
1
ln

ln ln
t
t

at fiber (2):
|
|
.
|

\
|
=
d
D
1
2
ln
To determine D
0
, D and D
1
and based
on the constant surface area:
H d d D H d d D 4
4 4
2
0
2 2
0
+ = + = t
t t
h d D D h d D D 4
4 4
2
0
2 2
0
= + = t
t t
h d d D h d d D 4
4 4
2
1
2 2
1
+ = + = t
t t
After the calculation of the strains
1
and
2
the flow stresses o
f1
and o
f2
can be determined from the flow curve of the drawn material.
2
2 1
f f
f
m
o o
o
+
=
In general, the total drawing force (F
D
) is comprised of the following:
Condition of successful drawing:
F
D
< force required for tearing the cup wall
2 1
f f B i D
F F F F F + + + =
where F
B
is the stress due to bending
F
f1
is the force to overcome friction under blank holder
F
f2
is the force to overcome friction at die edge
wall cup the of / ln
ut F
m
m
f
d
D
o q o <
(

|
|
.
|

\
|
o
r
max
o
r
max
o
r
+
o
r
max
4.3 Determining the blank size for axisymmetric
(rotationally symmetric) parts with large radii (r > 10 mm):
Bottom radii of > 10 mm must be given particular consideration when
determining the blank size. This takes place using Guldins (Pappuss)
theorem: The surface of a body of revolution generated by rotating a
curve around its axis is equal to the product of the generating curve and
the distance travelled by its geometric centroid at distance r
s
from the
axis of rotation.
4.4 Blank holder calculations:
( )
400
.
. 200
1
2
m
f
m
actual
S
d
p
o
|
(

+ =
o
fm
0
d
m
( )
4
.
2 2
0
t
e BH
d D A =
M e
r w d d . 2 . 2 + + =
Pressure
Area
Force
0
BH BH
A p F . =
D
0
d
1
d
2
d
3
Drawing
1
st
Redrawing
2
nd
Redrawing
d
mf
D
0
The parts which cannot be produced
in a single drawing are manufactured
by following redrawings:
mf
m
T
d
D
= | ratio drawing Total
4.5 Redrawing:

|
|
.
|

\
|
|
|
.
|

\
|
|
|
.
|

\
|
=
3
2
2
1
1
0
d
d
d
d
d
D
T
|
redrawing after diam.
redrawing before diam.
ratio Redrawing =
|
0
|
1
|
2
Intermediate annealing is taking place
between the redrawing operations
d
2
Reverse Redrawing
Direct Redrawing
before
after
d
2
d
1
d
1
Blank
holder
Die
4.6 Drawing tooling:
Drawing clearance, w
The drawing clearance, w, is half the
difference between the diameter of
the drawing ring and the diameter of
the punch.
Punch radius, r
p
,for cylindrical parts
Die edge curvature, r
M
For cylindrical parts:
Too small radii subject the sheet to additional strain. Too large radii lead
to the formation of wrinkles at the end of the draw, as then the blank
holder is no longer effective.
This depends upon the part being drawn.
With low drawing depths, a smaller r
M
must be selected as
otherwise, the area where the blank holder presses is too small.
The parts of the drawing rings which come into contact with the
sheet must be kept smoothly ground and polished to reduce
frictional forces.
Deep drawing tooling for the
second draw:
Structural design of drawing tooling
The structural design of drawing tooling is determined by the following factors:
1. The type of deep drawing
2. The press which is available (single or double-action presses)
If a deep drawing operation is carried out on a single-action press, then the
drawing ring must be fixed onto the ram and the blank holder must be operated
from the die cushion.
Drawing tooling for the second
darw for a single-action press
The principle of the deep drawing
process with a single-action press,
a)drawing punch,
b)Blank holder,
c)Drawing ring
To form the shape, the tensile-compressive stresses must be
accompanied by uniaxial or biaxial tensile and bending stresses created
by a suitable tooling design. The (draw) bead is generally put on the die
and the draw beads (lock beads) are arranged on the blank holder, with
gaps in the die to fit them.
3. Drawing tooling for irregular flat forms e.g. for automobile manufacturing
Drawing tooling for irregular, flat forms, such as those which occur often in
automobile parts, is characterised by difficult forming conditions. Instead of a
conventional drawing ring, a shaping drawing die is used which has the negative
form of the workpiece. This tooling is produced by casting, often full mould (lost
foam) casting followed by a chip-producing (cutting) finishing process.
The lock beads are of more importance than the draw beads and are
positioned in places where problems occur with varying stress ratios and
an associated material flow.
The draw beads and lock beads mean that the material flow can be
controlled, fine-tuned by FEM simulation and ultimately the toolmakers
experience, so that the defects of cracking, over-reduction of sheet
thickness and wrinkling can be avoided.
4.7 Defects during deep drawing:
4.8 Hydromechanical deep drawing (HDD)
Definitions
In hydromechanical deep drawing the circular blank to be formed (first draw) is
pressed directly onto the downward-moving drawing die by a pressurised water
pad giving it the exact shape of the drawing punch.
When a processing medium is
used in place of the rigid drawing
ring, as the punch is moved
down, this processing medium
produces pressure on all sides,
pressing the workpiece being
formed onto the punch.
Advantages of hydromechanical deep drawing:
The possible draw ratio is far better than with the conventional drawing
process. Draw ratios of up to | = 2.4 are possible, e.g. for St 13 and d/s= 100.
Conical and parabolic drawn parts are produced in one draw. In the
conventional drawing process, 4-5 drawing operations with 1-2 intermediate
anneals are often necessary for this kind of part.
The reduction in sheet thickness at the bottom radii is very low, enabling
thinner sheets to be deployed in many cases. Very small bottom radii can still
be drawn efficiently for this reason.
Blanks of varying thickness and different kinds of material can be processed
with the same tooling.
Production costs are lower than with conventional deep drawing.
Low tooling costs
Fewer steps in drawing
Lower annealing costs.
Any down-acting double-action press can be fitted with a hydromechanical
unit, even as a later addition. So expensive special-purpose machines are not
necessary.
Frictional forces occur between the punch and the workpiece which
transmit part of the drawing force onto the cup wall. This means that the
force passed across the bottom of the drawn part is lower and the area of
the workpiece under the most stress changes from the bottom of the
workpiece towards the drawing radius. This provides the following
advantages: