DRAWING
The two types of drawing process:-
• Rod, Wire & Tube drawing
An operation which the cross-sectional area of a bar or
tube is reduced by pulling it through a converging die.
The die opening may be any shape. Wire drawing
involves smaller diameter materials than rod drawing,
with sizes as small as 0.025mm.
• Deep Drawing
Deep drawing is a sheet-metal forming operation used to
make cup-shaped, box-shaped or other more complex-
curved, hollow-shaped parts. The cup is deeper than
one-half its diameter. It is performed by placing a sheet-
metal blank over a die cavity and then pushing the metal
into the opening with a punch. Common parts made by
deep drawing include beverage cans, sinks, pots & pans,
containers of all shape and sizes and automobile body
panels.
Mechanics of Deep Drawing
1) A blank diameter Db is drawn into a die by
means of a punch of diameter Dp. Punch &
diameter must have corner radii, given by Rp
and Rd.
2) The sides of the punch and die are separated
by a clearance c. The clearance is about 10%
greater than stock thickness i.e. c = 1.1t.
3) The punch applies a downward force F to
accomplish the deformation of the metal and a
downward holding force Fh is applied by the
blankholder.
4) As the punch proceeds downwards toward its
final bottom position, the work experiences a
complex sequence of stresses and strains as it
is gradually formed into shape defined by the
punch and die cavity.
• The Significant independent variables
in deep drawing are:-
• Properties of the sheet metal
• The ratio of blank diameter to punch
diameter
• Clearance between the punch and the die
• Punch and die corner radii.
• Blankholder force.
• Friction and lubrication at the punch, die
and workpiece interfaces.
• Speed of the punch.
Analysis of Deep Drawing
Two principal actions usually take place in deep drawing (i)
biaxial stretching over a punch; in which both principal
strains are tensile and (ii) drawing-in of a flange into a die
cavity in which one principal strain is tensile and the other is
compressive.
During the course of deep drawing, the following five
process takes place:-
1. Pure radial drawing in of the blank between die &
blankholder.
2. Bending & sliding over the radius at the entry to the die.
3. Stretching between the punch & the die.
4. Bending & sliding over the radius at the shoulder of the
punch.
5. Possibly stretching & sliding over the punch nose if it is not
flat.
If the clearance between the punch & the die is less than the
blank thichness as it enters the die, the blank is "Ironed" as
it passes into the cup wall.
Deep Drawability / Limiting Drawing Ratio (LDR)
The limiting drawing ratio (LTR) is the
maximum blank diameter that can be drawn
into a cup without failure.
Some of the practical considerations
which affect drawability are:
1. die radius - should be about 10 times sheet
thickness.
2. Punch radius - a sharp radius leads to local
thinning & tearing
3. Clearance between punch and die - 20 to 40
percent greater than the sheet thickness.
4. Hold- down pressure
5. Lubrication - to reduce friction in drawing
Where R is known as the normal anisotropy (plastic anisotropy or strain ratio)
Since thickness measurements are difficult to make with precision on
thin sheets, the equation can be rewritten using the constancy of
volume relationship:-
Where l refers to the gauge length of the sheet specimen. To calculate R, the
final length and width in a test specimen are generally measured at an
elongation of 15% to 20%., or for materials with lower ductility below the
elongation where necking begins.
Ex
A tension test on a special deep-drawing steel
showed a 30% elongation in length and a 16%
decrease in width. What limiting drawing ratio
would be expected for the steel.
Ex
Estimate the limiting drawing ratio (LDR) that you
would expect from a sheet metal which when
stretched by 23% in length, decreases the
thickness by 10%. Assume volume constancy
for the test specimen.
• WASIAT NABI JUNJUNGAN KPD SAIDINA ALI R.A
• Wahai Ali, Bagi orang mukmin ada 3 tanda-tandanya
• 1) Tidak terpaut hatinya pada harta benda dunia
2) Tidak terpesona dengan pujuk rayu wanita
3) Benci terhadap perbualan dan perkataan sia-sia
• Wahai Ali, Bagi orang alim itu ada 3 tanda-tandanya
• 1) Jujur dalam berkata-kata
2) Menjauhi segala yang haram
3) Merendahkan diri
• Wahai Ali, Bagi orang yang takwa itu ada 3 tanda-tandanya
• 1) Takut berlaku dusta dan keji
2) Menjauhi kejahatan
3) Memohon yang halal kerana takut jatuh dalam keharaman
• Wahai Ali, Bagi orang yang jujur itu ada 3 tanda-tandanya
• 1) Merahsiakan ibadahnya
2) Merahsiakan sedekahnya
3) Merahsiakan ujian yang menimpanya
• Wahai Ali, Bagi ahli ibadah itu ada 3 tanda-tandanya
• 1) Mengawasi dirinya
2) Menghisab dirinya
3) Memperbanyakkan ibadah kepada ALLAH s.w.t.
DETERMINING THE BLANK SIZE
2 d
D d 4dh when is 20 or more
r
2 d
D d 4dh 0.5r when 15 20
r
2 d
D d 4dh r when 10 15
r
2 d
D (d 2r ) 4d (h r ) 2r (d 0.7 r ) when 10
r
r = corner radius on the punch
h = height of the shell
d = outer diameter of the shell
D = blank diameter
ENGINEERING ANALYSIS OF DRAWING
. Measures of Drawing
Drawing Ratio
D
Drawing Ratio ( DR)
d
The maximum limit on the drawing ratio value is 2.0
Reduction of a shell may be calculated as follows:
Dd
Reduction (r )
D
The value of reduction (r) should be less than 0.5
Thickness Ratio
t
Thickness Ratio (S )
D
Thickness ratio must be greater than 1%.
Ex: A cup is to be drawn to a diameter of 77
mm and 38 mm deep in a 1 mm thick
material. Estimate the blank diameter and
the drawing ratio. Radius is 2mm
Ex: A drawing operation is used to form a
cylindrical cup with inside diameter 75 mm
and height 50 mm. The starting blank size
is 140 mm and the stock thickness is 2
mm. based on these data is the operation
feasible?
DRAWING FORCE & HOLDING FORCE
D
Fd D t t 0.7
d
D d 2.2t 2 Rd
2 2
Fh 0.015 y
Fd Drawing Force
Fh Holding Force
D Blank diameter
d Punch diameter
t tensile strength
y Yield strength
Rd die corner radius
Ex: A cup is to be drawn to a diameter of 77
mm and 38 mm deep in a 1 mm thick
material. Estimate the blank
diameter,drawing ratio and the drawing
force if tensile strength is 432 MPa.
Radius is 2mm.
Ex: A drawing operation is used to form a
cylindrical cup with inside diameter 75 mm
and height 50 mm. The starting blank size
is 140 mm and the stock thickness is 2
mm. based on these data is the operation
feasible?
Ex: A cup is to be drawn to a diameter of 50 mm and 20
mm deep in a 0.6 mm thick material with a radius of 6
mm. estimate the blank diameter, drawing ratio, the
holding force and the drawing force if tensile strength
and yield strength is 330 MPa and 270 MPa. The die
corner radius is 5 mm.
Ex: A drawing operation to form a cylindrical cup with inside
diameter of 90 mm has a drawing ratio of 1.6. Find the
size of starting blank size and the thickness of the
material for the operation if the ratio of thickness to
diameter is constant at 1.78%. Find also the drawing and
holding force if the die corner radius is 17 mm. take
tensile and yield strength as 490 MPa and 315 MPa.
Factors Affecting Drawing
The various factors that affect the metal flow during
drawing are as follows:-
• 1. Ductility. Ductility is the ability of the metal to under go a change in shape without
fracturing. Yield strength is the point at which permanent change of shape occurs in a
metal. A low yield strength is desirable so that metal flow can begin easily without
tearing near the punch radius.
• 2. Force of friction. The force of static friction between the work piece and draw die
surfaces must be overcome in drawing operation. The force of blank holder adds
significantly to the force of static friction. ONce the static friction is over-come by the
start of the blank movement continuous movement of punch is quite important
because the force needed to over-come dynamic friction is less than that needed for
static friction.
• 3. Blank holder pressure. The blank holder pressure should be only high enough to
prevent wrinkling of the metal. Too high values of blank holder pressure causes
higher frictional forces and may cause the metal to be restricted and may result in
tearing of the cup wall.
• 4. Lubricants. In drawing a lubricant is generally applied to reduce friction. Shallow
draws in light stampings can be produced with little or no lubrication. But when forces
become larger and scoring, wrinkling and tearing become a problem, a lubricant
should be used. When pressures are low straight mineral oil, general purpose soluble
oil, or a diluted soap solution can give satisfactory
Some of the defects encountered in
deep drawing formed parts
(a) Orange peel effect
(b) Earing
(c) Tearing
(d) Surface scratches
(e) Wrinkling in the wall
(f) Wrinkling in the flange
Orange peel effect
When a coarse grain material is drawn, the grains will often
manifest themselves as a rough surface on those portions of
the component which have undergone the greatest amount of
deep drawing and which have not been. in contact with the die
face. This roughness resembles to some extent the surface of
an orange. A fine grain material will not experience such a.
defect.
Earing
This is the formation of irregularities (called ears) in the
upper edge of a deep drawn cup, caused by anisotropy in the
sheet metal. If the metal is perfectly isotropic, ears do not
form.
TEARING
Tearing is an open crack in the vertical wall, usually near the base of the
drawn cup, due to high tensile stresses that cause thinning and failure of
the metal at this location. This type of failure can also occur as the metal is
pulled over a sharp die corner.
Surface scratches
Surface scratches can occur on the drawn part if the punch and die are
not smooth or if lubricant is insufficient.
Wrinkling in the wall
If and when the flange is drawn into the cup, these ridges
appear in the vertical wall.
Wrinkling in the flange
Wrinkling in a drawn part consists of a series of
ridges that form radially in the undrawn flange of
the work part due to excessive buckling.
IRONING
During ironing the inside diameter of the cup remains constant and
the wall thickness is reduced markedly. The force to cause the
ironing deformation is transferred from the punch to the cup via the
pressure exerted on the bottom and friction at the interface of the
cup and the ironing die. Ironing operations require careful
engineering to ensure that the punch force does not cause the
bottom of the cup to tear-off. Typical examples are beverage cans
and artillery shells.
REDRAWING
In redrawing operation, an already drawn cup is the raw material,
which is further drawn in successive steps. During the downward
stroke of the punch, the pre-drawn cup is forced through the die
opening and this squeezes the cup to a smaller diameter. The
amount of drawing during the redrawn is always less than the initial
drawing stage. Typical products are food containers, fountain-pen
caps, oil filter housing & shock-absorber piston.
