LPG CYLINDER

MANUFACTURING
DEFECT
Earing During Deep Drawing Operations

Prepared By: MRSK

Problem Definition

■ During deep drawing operation on metal sheets, earing

occurred and extra ears produces metal chips. Metal
chips further causes gauges/cuts on next blanks.
Observations

■ Sheet thickness changed from 2.7 mm (+/-) to 2.5 mm (+/-)

■ Earing during deep drawing operation & chips formation
Important Parameters
Factors Changes Remarks
o Chemical compositions Nothing significant As per MTC given
o % elongation 31% As per MTC
o Punching pressure & Adjusted
Holding pressure
o Punch & Shaft clearance No changes
o Drawing Speed/ 3.3 pcs per munities (200 pcs/hr)
Production rate
o Lube oil Adjusted
Field tests
■ Conducted elongation test from HR coil at 00, 450, 900 against rolling
direction
■ Checked earing pattern after deep drawing operations
Test Results (Baosteel HR Coil: Heat No# 39100860302, Test date: 11-02-2020)
Sl Sample % elongation Yield strength UTS Yield ratio
a S-01-00 19.5 17.2 KN 22.95 KN 0.75
b S-01-45 25.0 18.9 KN 24.9 KN 0.76
c S-01-90 26.5 17.54 KN 25.1 KN 0.70
Findings: Elongation is less than 31% (%e = 31% as per MTC)
Calculating Normal Anisotropy (R)
Tensile test coupon at 00, 450, 900

00 450 900
Initial Width , Wi 18.61 mm 19.81 20.41
Initial Thickness, Ti 2.49 2.53 2.45
Final Width, Wf 16.23 15.58 17.81
Final Thickness, Tf 1.42 1.265 1.57

R0 0.2436
R45 0.346
R90 0.306
Ravg 0.298 (Typical Range 0.8 -1.0)
Formula
R= { ln (Wi / Wf )} / { ln (Ti / Tf )}
 Earing pattern against rolling direction
∆R = (R90 +R0 - 2 R45) /2
= (0.306 + 0.2436 – 2x 0.346)/2
= - 0.0712
(∆R < 0)
Earing pattern against rolling direction from
Production

At 450

At 00
Test Pictures

Body Temp.
after deep
drawing