1.
Material Selection:
● Materials commonly used in deep drawing processes are steel (SS), aluminum, and brass,
among others. Each material has its own forming characteristics.
○ Steel (SS): Strong, but requires higher draw force.
○ Aluminum: More malleable, requires lower force.
○ Brass: Similar to steel in terms of force but more expensive.
3. Draw Speed:
Draw speed is typically set to balance between part quality and efficiency. Higher speeds may result
in material tearing, while slower speeds can reduce productivity.
● Typical Range: 10 - 100 mm/s
● Depends on material:
○ Aluminum can be drawn faster.
○ Steel might need slower speeds to avoid fracture.
4. Punch Size:
The punch size should be slightly smaller than the desired final product size to accommodate the
stretching of the material.
Example:
● Punch size P might be 10 mm for a final drawn part size of 12 mm.
5. Die Clearance:
Die clearance is the gap between the punch and die, which depends on the material's thickness.
General Rule:
● Die Clearance is typically around 10-15% of the material thickness.
Example:
● For a 1 mm thick sheet, die clearance should be around 0.1-0.15 mm.
The binder force (also known as blank holder force) in deep drawing is crucial for controlling
material flow. If it's too low, it can cause wrinkling; if it's too high, it can cause tearing or fracture.
The ideal binder force depends on the material type, sheet thickness, and geometry of the part.
General Guidelines
The recommended draw speed in the deep drawing process depends on the material’s formability
and the overall processing conditions. Materials with higher ductility and malleability tend to be
drawn at faster speeds, while materials that are more brittle or have lower formability need slower
drawing speeds to avoid defects like cracks or tearing.
Here's a general guideline for recommended draw speeds based on common sheet metal
materials:
1. Aluminum (Al)
● Draw Speed: 50 - 100 mm/s
● Aluminum has high formability and is generally easier to draw. You can achieve higher
speeds compared to steel or brass. However, it still requires some care, especially with alloys that
might be more prone to strain hardening.
2. Steel (Stainless Steel - SS, Mild Steel)
● Draw Speed: 10 - 50 mm/s
● Stainless steel and mild steel are more rigid and less ductile than aluminum, so slower draw
speeds are recommended to reduce the risk of cracks or tearing. Higher speeds may lead to
increased friction, heat, and strain hardening, which can cause defects.
3. Brass
● Draw Speed: 20 - 50 mm/s
● Brass has a moderate level of formability. While it’s not as ductile as aluminum, it can still be
drawn at moderate speeds. You have to balance speed and tooling setup to prevent excessive
wear.
4. Copper
● Draw Speed: 10 - 30 mm/s
● Copper is highly ductile, but it also has a tendency to strain harden. Slower speeds are used
to control the material's flow and prevent work hardening during the process.
5. Titanium
● Draw Speed: 5 - 20 mm/s
● Titanium is much stronger but less ductile, requiring slower drawing speeds. It has high
strength but poor formability compared to other metals, so draw speeds need to be controlled to
avoid cracking.
6. Magnesium
● Draw Speed: 20 - 60 mm/s
● Magnesium is lighter than aluminum but has similar formability. It can be drawn at faster
speeds, but attention must be given to lubrication and temperature, as magnesium is more prone to
tearing if not properly handled.
7. Zinc
● Draw Speed: 30 - 70 mm/s
● Zinc has good formability and can be drawn at relatively higher speeds compared to steel or
titanium. However, care should be taken to avoid excessive strain hardening.
General Factors That Influence Draw Speed:
1. Material Thickness: Thicker materials require slower speeds to ensure proper material flow
and reduce the likelihood of failure.
2. Tooling and Die Setup: Poorly designed dies can cause excessive friction, which might
require slower speeds.
3. Lubrication: Adequate lubrication helps control friction and heat, allowing for faster speeds
without compromising quality.
4. Temperature: Higher temperatures (especially for materials like aluminum and magnesium)
can improve formability and may allow for higher speeds.
Lubrication is crucial in the deep drawing process, as it reduces friction, minimizes wear on tooling,
and helps control material flow, preventing issues like tearing, wrinkling, or galling. The type of
lubrication used in sheet metal deep drawing depends on the material being processed and the
formability of that material. Below are some commonly recommended lubricants for various
materials used in the deep drawing process.
1. Aluminum
Aluminum has good formability but is prone to galling due to its softness. The key is to use
lubricants that reduce friction and prevent sticking.
● Recommended Lubricants:
○ Water-based emulsions: These are commonly used because they provide good cooling
and lubrication. Examples include water-based oils or synthetic lubricants.
○ Synthetic lubricants: These are formulated for aluminum to reduce the likelihood of galling
and improve surface finish.
○ Oil-based lubricants: Light oils or mineral oils with anti-wear additives are often used for
deep drawing aluminum.
○ Graphite-based lubricants: In some cases, a light coating of graphite may be used for dry
lubrication, particularly when high-speed processes are involved.
2. Steel (Stainless Steel - SS, Mild Steel)
Steel requires more robust lubrication to handle its higher frictional properties and ensure proper
material flow without causing excessive tool wear.
● Recommended Lubricants:
○ Oil-based lubricants: Heavy-duty mineral oils or drawing oils are often used for steel.
These oils often contain additives like sulfur or chlorine to enhance performance during the deep
drawing process.
○ Water-soluble oils: These oils are diluted with water and provide a combination of cooling
and lubrication. They're useful for reducing heat generation and friction.
○ Semi-synthetic lubricants: A blend of synthetic and mineral oils can provide good
lubrication and cooling properties for mild steel and stainless steel.
○ Phosphate-based lubricants: These are commonly used with steel to improve lubrication
and surface finish.
○ Graphite-based lubricants: In some cases, especially for high-speed processes, graphite
or molybdenum disulfide (MoS2) is used to reduce friction.
3. Brass
Brass is less prone to galling compared to aluminum, but it is still necessary to reduce friction to
ensure smooth deep drawing.
● Recommended Lubricants:
○ Oil-based lubricants: Brass typically uses light oils or mineral oils, with anti-wear additives
to improve the forming process and avoid galling.
○ Water-based emulsions: These can also be used, but care must be taken to avoid
corrosion.
○ Graphite-based lubricants: Dry lubricants like graphite are often used for brass, especially
in high-speed processes.
○ Phosphate-based lubricants: A good choice for improving lubricity and minimizing friction
during deep drawing of brass.
4. Copper
Copper, like brass, is highly prone to galling, and lubrication is critical to prevent material sticking to
the die.
● Recommended Lubricants:
○ Oil-based lubricants: Mineral oils or synthetic oils with anti-wear and anti-galling properties
are essential. Some copper alloys may also benefit from oils that contain sulfur or chlorine for
enhanced lubrication.
○ Water-based emulsions: These are effective for cooling but need to be carefully controlled
to prevent corrosion of the copper.
○ Graphite-based lubricants: Graphite, often in combination with oil, is used in deep drawing
copper.
○ Wax-based lubricants: In some cases, waxes or wax-based compounds are used, as they
provide effective lubrication and can help with high-speed drawing.
5. Titanium
Titanium is known for its strength but poor formability. Due to its tendency to gall, lubrication is
crucial.
● Recommended Lubricants:
○ Mineral oils with extreme pressure additives: Titanium requires robust lubrication, often
using oils designed for high-pressure applications to reduce friction and prevent galling.
○ Graphite-based lubricants: Light graphite or molybdenum disulfide can be used for dry
lubrication, particularly in higher-speed processes.
○ Water-soluble lubricants: These can be used for cooling and lubrication but need to be
chosen carefully to avoid corrosion of titanium.
○ Synthetic lubricants: Synthetic oils designed for metals with poor formability like titanium
may be necessary to control friction and heat generation.
6. Magnesium
Magnesium is a lightweight material that is more prone to surface oxidation and galling. Lubrication
is critical for both reducing friction and preventing oxidation during forming.
● Recommended Lubricants:
○ Water-based emulsions: These are often used for cooling and lubrication. Some
formulations contain corrosion inhibitors to prevent magnesium oxidation.
○ Oil-based lubricants: Magnesium requires lubricants that can withstand high temperatures
and reduce friction during deep drawing. Mineral oils with anti-wear additives are commonly used.
○ Synthetic lubricants: Special synthetic oils that provide high lubrication performance and
temperature resistance are often used for magnesium.
7. Zinc
Zinc is softer than steel but harder than aluminum, and it requires lubrication to prevent excessive
friction and wear.
● Recommended Lubricants:
○ Oil-based lubricants: Mineral oils with anti-wear additives are often used for deep drawing
zinc to reduce friction and enhance material flow.
○ Water-based emulsions: Water-soluble oils can also be used for cooling and lubrication,
particularly in continuous drawing operations.
○ Graphite-based lubricants: Dry graphite can be used in some cases to prevent material
sticking and reduce friction.
Summary of Lubricants for Different Materials:
Material Recommended Lubricants
Aluminum (Al) Water-based emulsions, synthetic oils, graphite-based
Stainless Steel (SS), Oil-based lubricants, water-soluble oils, semi-synthetic
Mild Steel lubricants, graphite-based
Brass Oil-based lubricants, water-based emulsions, graphite-based
Copper Oil-based lubricants, water-based emulsions, graphite-based,
wax-based
Titanium Mineral oils with extreme pressure additives, graphite-based,
water-soluble lubricants
Magnesium Water-based emulsions, oil-based lubricants, synthetic
lubricants
Zinc Oil-based lubricants, water-based emulsions, graphite-based
The surface finish of the punch and die in a deep drawing die is critically important for the
quality of the formed part and the performance of the tooling. A good surface finish helps reduce
friction, minimizes tool wear, and prevents surface defects on the drawn sheet metal.
1. Punch Surface Finish
● Purpose: The punch contacts the inner surface of the drawn part. A smooth punch surface
helps reduce friction and prevents tearing or wrinkling of the material.
● Recommended Surface Finish:
○ Ra (Roughness Average): 0.2 – 0.4 µm
○ Finish Grade: Fine ground or polished
○ Finishing Methods: Grinding, polishing, or hard chrome plating
2. Die Surface Finish
● Purpose: The die comes into contact with the outer surface of the drawn blank. A smooth
die surface ensures even material flow and a high-quality outer surface.
● Recommended Surface Finish:
○ Ra: 0.1 – 0.2 µm (for critical surfaces)
○ Ra: up to 0.4 µm (for general-purpose forming)
○ Finish Grade: Polished to near-mirror or mirror finish
● Finishing Methods:
○ Grinding and polishing
○ Lapping for ultra-smooth finish
○ Hard coatings or nitriding to improve wear resistance
● Why It's Critical:
○ Poor surface finish on the die can lead to scratches, material sticking, or orange peel
effect on the final part.
○ A highly polished die surface is especially important for cosmetic parts (e.g., appliance or
automotive panels).
3. Blank Holder / Binder Surface Finish
● Ra: 0.4 – 0.8 µm
● Typically does not need to be as smooth as punch and die, but must still be even to ensure
consistent holding pressure.
● Excessively smooth surfaces might not grip the material properly, leading to slippage or
wrinkling.
Summary Table
Component Surface Finish (Ra) Finish Type Notes
Punch 0.2 – 0.4 µm Polished / Chrome Mirror finish for exposed parts
Die 0.1 – 0.2 µm Mirror Polished Critical for outer surface
appearance
Binder 0.4 – 0.8 µm Smooth Ground Prevents wrinkles, allows holding
grip
Additional Tips
● Use proper lubrication in combination with surface finish to reduce tool wear.
● Monitor wear over time—surface finish degrades with use, affecting part quality.
● Consider tool coatings (e.g., TiN, DLC, CrN) for better durability and reduced maintenance.
