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deepdrawn|deepdrawingprocess|sheetdrawingmetal|

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SheetmetalDeepdrawingtechnologyisoneofthemostchallenging
processinmanufacturing.Successfuldeepdrawingprocessdependson
manyfactors.
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Tool&DieMaking
Articles
BendRadius
DeepDrawn
FineBlanking
Formular
Progressionstriplayout
Slugpullingprevention
TooldieDesign
Tooldiedesignbook
TechnicalBookStore

JigandFixture
JigsandFixtureDesign

Materialstreatment
Annealingmetal
Casehardening
Density
ElectricalConductivity
heattreatmentprocess
heattreatingsteel
ThermalExpansion
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Commentproblems

Drawcomputation

Reductionpercentage

Thesheetmetaldeepdrawntechnologyisoneofthemostchallengingprocessin
manufacturing.Thesizes,shapes,thicknessanddeepdrawnmetalusedtoproduces
sheetmetaldeepdrawnpartscoveradiverserangeofvariables.Individualvariables
shouldbeevaluatedcarefullytodeterminetheoptimummanufacturingmethod.
Regardlessofthemanyfactorsinvolvedaffectingthedrawquality,
themostimportantelementtoasuccessfulsheetmetaldeepdrawingoperationisthe
smoothnessofsheetmetalflow.Thefollowingarekeyelementsaffectingmetalflow
duringdeepdrawingprocessandeachofthemshouldbeconsideredwhendesigningor
troubleshootingsheetmetaldeepdrawingstampingtools:
Typeofmaterialusedanditsthickness.=Indeepdrawingprocess,thickermaterialsarestiffer,
theycanbegrippedbetterduringdeepdrawing.Thickermaterialsalsohavemorevolume,sotheycan
stretchlongerdistancesduringdeepdrawingprocess(deeperdraw).
Toolsurfacefinish&typeofLubricantused=Diesurfacefinishesandlubricantsareimportantto
reducesthefrictionbetweentoolsurfacesandmetalbeendrawn,itallowingmaterialstoflowthrough
toolsmoreeasily.Dietemperaturescanaffecttheviscosityoflubricants.Slowerdeepdrawingspeed
givesbettermetalflow.
Blanksizeandshape=Blanksizesandshapesthataretoolargecanrestrictmetalflow,andthe
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geometryofpartsaffectstheabilityofmetaltoflowduringdeepdrawingprocess.
Material
Aluminum
Alucomparisontable
AluminumTempering
CarbonSteel
Copperalloy
Lowalloys
Materialnations&
Equivalents
Nickelalloys
StainlessSteel
StainlessSteel
comparisontable
ToolSteelequivalent
TungstenCarbide
WroughtstainlessSteel

Manufacturing
ConversionCharts
DrillAngle
Drillsize
EnergyEfficiency
MathArea
MachiningCuttingTime
Technicalarticles
WorkDone
Velocity

Punchingspeed=sufficientpunchingspeedallowstimeformaterialstoflowthroughthetool.Corner
crackingwillalwaysoccurifpressspeedistoolfastindeepdrawingprocess.
Drawradii=Radiusonthedrawdiewherethematerialflowthrough,toobigtheradiiwillresult
wrinklingwheretoosmallwillcreatescrackingatbottomradiusofdrawnpart.
Drawratio=Referstotheabilityofamaterialtoflowordraw.Affectingthedrawdepthandsizeper
anysingledraw.
Drawbeadheightandshape=Tocontrolmetalflowandgrippingpressureindeepdrawingprocess,
drawbeadheightandshapecancausematerialstobendandunbendtocreatesrestrictiveforcesgoing
intoatool.Increasingpressurewillexertsmoreforceonamaterial,creatingmorerestraintonmaterial
goingintothetool.
Causesofcommonproblemsinthedeepdrawing.

highspeedpress
bestmachinerysupplierinChinagoodquality,performanceequmen

Metalfractureduringdeepdrawingprocess
1.Deepdrawingradiitoosmall,creatingresistancetometalflowtocauseunduethinningorfracture.
Correctbyincreasingdieradiusorbychangingdieentrancetoconicalorellipticalshape.
2.Clearancebetweenpunchanddietoolittle,toogreatoruneven.
GeometricTolerancing 3.Blankholderpressuretoogreat.
4.Lubricantinadequateorunsuitable.
GDT
5.Punchnoseradiustoosmall.
TolerancechartISO
SurfaceRoughness
Wrinklesontopedgeorflange
SurfaceTexture
1.Blankholderpressuretootight.
2.Drawradiustoolarge.
3.Punchnoseradiustoolarge.
QualityControl
4.Wrinklesonthesideofcuporflangecausedbyburronblankorbyanunbalancedblankholder
AQL
ProcessCapabilityCPK pressure.
Samplingplan
LevelI,II,III
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Uneventoprimorflange
1.Nicksorburralongtheperipheryoftheblank.
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EngineeringPlastic
Machiningofplastic
Selectionofplastic

2.Punchdieorblanklocatornotconcentric.Toomuchmaterialpulledintothediebyoffcenterforming
punchpreventingformingofanevencupdepthorflange.
3.Blankholderexertinganunbalancedforceontheblank,permittingthematerialflowunevenlyintothe
die.
Flangewrinkled,Puckered.
1.Blankthicknesswrongoroutoftolerance.
2.Drawradiustoolarge.
3.Clearancebetweenpunch&Dietoolargeforthestockthickness.
3.Depthofpreviousdrawntooshortorredrawoperationtoodeep.Orsidewallofdrawncupbeingtinned
down.

Fractureaybottomofredrawncup
1.Drawradiusandblankholdingsurfacescratched,nickedorgalled.Restrictingmetalflowintothedie.
2.Punchnoseanddrawradiustoosmall.
3.DiameterReductiontoogreat.
FractureinoratFlangeofdrawncup.
1.Punchanddieclearancetoosmall.
Excessmaterialattopofdeepdrawnshell
1.Materialthicknesstoogreatorpunchdieclearancetoosmalloruneven.
2.Punchnoseradiuslargerthancupbottomradius,causesexcess
sheetmetaltoflowupsidewall.
3.Drawradiustoolarge,permittingwrinklestostartthatenlargeduringredrawofcup.
Deepdrawnprocesscomputation

Bydefinition,adrawpiecepartwhichrequiresonly
onedrawoperationisconsideredtobeashallow
draw,andadrawpiecepartwhichrequiremore
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TableAnumberofdraw
H/D

<0.75

0.751.5

1.53.0

3.04.7

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Catheter
Tip
Moulds

thanonedrawingoperationisconsidertobedeep
draw.Inthenutshell,thenumberofdrawsindeep
drawingprocesscanbeestimatedbytableA.

Nickelforms,
Machined
Stainless
HighQuality,
FastService

H=Insideheight
D=meanDiameter
N>4Thickness
P=Numberofdraws

Deepdrawnreductionpercentages
Whenasheetmetalpartsdrawpieceisdrawnfromaflatblank,thediameterofthedrawpieceis
smallerthanthediameteroftheflatblank.Thedifferenceindiametercanbeexpressasapercentage
oftheoriginal1stblankdiameter.
Material=Steel
Sheetmetal
Thickness
1stdraw
2nddraw
3rddraw
4thdraw
(inch)
<0.063
4048
2025
1820
1618
0.0630.125
4048
1518
1415
1314
0.1250.187
4048
1215
1112
1011
0.1870.25
4048
1013
910
89
>0.25
4048
810
78
67
Material=Brass
<0.063
4450
2029
1823
1820
0.0630.125
4450
1623
1517
1215
0.1250.187
4450
1417
1214
1113
0.1870.25
4450
1014
911
810
>0.25
4450
911
89
78

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