Deep Drawing Lec 1
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Transcript of Deep Drawing Lec 1
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Deep Drawing
Deep drawing Deep drawing defects Deep drawing operations Deep drawing calculations
DR. Ramadan EL-Gamsy
![Page 2: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/2.jpg)
Deep Drawing
Parts are made by having punch forces on a flat sheet-metal blank into a die cavity, a process called deep drawing
Also used to make parts that are shallow or have moderate depth
A round sheet-metal blank is placed over a circular die opening and is held in place with a blank holder
DR. Ramadan EL-Gamsy
![Page 3: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/3.jpg)
DR. Ramadan EL-Gamsy
![Page 4: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/4.jpg)
If the depth of the item created is equal to or greater than its radius, then the metal forming process called deep drawing.
DR. Ramadan EL-Gamsy
![Page 5: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/5.jpg)
Examples
DR. Ramadan EL-Gamsy
![Page 6: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/6.jpg)
Examples
DR. Ramadan EL-Gamsy
![Page 7: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/7.jpg)
Deep drawing
DR. Ramadan EL-Gamsy
![Page 8: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/8.jpg)
Defects in Drawing
A number of defects in drawing can occur, which include: (a) Wrinkling in the flange occurs due to compressive buckling in the circumferential direction (blank holding force should be sufficient to prevent buckling from occurring). (b) Wrinkling in the wall takes place when a wrinkled flange is drawn into the cup or if the clearance is very large, resulting in a large suspended (unsupported) region. (c) Tearing occurs because of high tensile stresses that cause thinning and failure of the metal in the cup wall. Tearing can also occur in a drawing process if the die has a sharp corner radius. (d) Earring occurs when the material is anisotropic, i.e. has varying properties in different directions. (e) Surface scratches can be seen on the drawn part if the punch and die are not smooth or if the lubrication of the process is poor.
DR. Ramadan EL-Gamsy
![Page 9: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/9.jpg)
Defects in Drawing
DR. Ramadan EL-Gamsy
![Page 10: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/10.jpg)
Drawing dies
DR. Ramadan EL-Gamsy
![Page 11: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/11.jpg)
DR. Ramadan EL-Gamsy
![Page 12: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/12.jpg)
Deep Drawing for cans
DR. Ramadan EL-Gamsy
![Page 13: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/13.jpg)
Deep drawing with flange
DR. Ramadan EL-Gamsy
![Page 14: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/14.jpg)
Deep Drawing
DR. Ramadan EL-Gamsy
![Page 15: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/15.jpg)
Drawing steps
DR. Ramadan EL-Gamsy
![Page 16: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/16.jpg)
Drawing steps
DR. Ramadan EL-Gamsy
![Page 17: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/17.jpg)
Redrawing die
DR. Ramadan EL-Gamsy
![Page 18: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/18.jpg)
Deep Drawing Calculations
Blank diameter Diameter ratio Force calculations
DR. Ramadan EL-Gamsy
![Page 19: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/19.jpg)
Blank dimensions
Trimming allowance
DR. Ramadan EL-Gamsy
Allowances for edge trimming for cylindrical cups without flange. Total height in
mm Allowance for height to diameter ration h/d
0.5 -0.8 0.8 -1.6 1.6 -2.5 2.5 -4.0 10 1.5 1.8 2.3 3 20 2.2 3 3.7 4.5 50 3.5 4.5 6 7
100 5 6.5 8.5 10 150 6.5 8 10 12 200 7.5 9.3 12 15 250 9 11 13.5 16 300 10 13 15 18
![Page 20: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/20.jpg)
Blank volume
DR. Ramadan EL-Gamsy
![Page 21: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/21.jpg)
Blank Size Determination
For final dimensions of drawn shape to be correct, starting blank diameter Db must be right
Solve for Db by setting starting sheet metal blank volume = final product volume
To facilitate calculation, assume negligible thinning of part wall
DR. Ramadan EL-Gamsy
![Page 22: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/22.jpg)
Number of stages
Maximum height to diameter ratio h/d for S/D %
No of drawing stages
Relative materials thickness s/D % 2 - 1.5 1.5 -1.0 1.0 - 0.6 0.6 – 0.3 0.3 – 0.1
1 0.9..0.77 0.84…0.65 0.7….5.57 0.62….0.57 0.52..0.45 2 1.88..1.54 1.6….1.32 1.36….1.10 1.13….0.94 0.96…083 3 3.5…..4.3 2.8…..2.2 2.3…..1.80 1.90….1.50 1.60…1.30 4 5.0…..4.8 4.3……3.5 3.60….2.90 2.90…2.40 2.40….2.00 5 8.9…6.6 6.6….5.1 5.20….4.10 4.10…3.30 3.30….2.70
DR. Ramadan EL-Gamsy
![Page 23: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/23.jpg)
Diameter ration m
Diameter ratio m= d/d0
Diameter Ratio M
Relative materials thickness s/D % 2 - 1.5 1.5 -1.0 1.0 - 0.6 0.6 – 0.3 0.3 – 0.1
M1 0.48 – 0.5 0.5 – 0.53 0.53-0.55 0.55-0.58 0.58- 0.60 M2 0.73 – 0.75 0.75 – 0.76 0.76 – 0.78 0.78 0.79 0.79 -080 M3 0.76-0.78 0.78 – 0.79 0.79 – 0.8 0.80- 0.81 081-082 M4 0.76 -0.8 0.8 – 0.81 0.81 -0.82 0.82 -0.82 0.83 – 0.85 M5 0.8 – 0.82 0.82 -0.84 0.84- 0.85 0.85-0.86 0.86 – 0.87
DR. Ramadan EL-Gamsy
![Page 24: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/24.jpg)
Force calculations
Item Stage Formula Cylindrical cup without flange
1st Drawing F=π d1 s σult K1 2nd Drawing F=π dn s σult K2
DR. Ramadan EL-Gamsy
![Page 25: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/25.jpg)
Force Calculations
Relative materials thickness s/D %
M1 0.45 0.48 0.5 0.52 0.55 0.60 0.65 0.70 0.75 0.80
5.0 0.95 0.85 0.75 0.65 0.60 0.50 0.43 0.35 0.28 0.20 2.0 1.1 1.00 0.90 0.80 0.75 0.60 0.50 0.42 0.35 0.25 1.2 1.10 1.00 0.90 0.80 0.68 0.56 0.47 0.37 0.30 0.8 1.10 1.00 0.90 0.75 0.60 0.50 0.40 0.33 0.5 1.10 1.00 0.82 0.67 0.55 0.45 0.36 0.2 1.10 0.90 0.75 0.60 0.50 0.40 0.1 1.10 0.90 0.75 0.60 0.50
K1 for first stage drawing
DR. Ramadan EL-Gamsy
![Page 26: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/26.jpg)
Force Calculations
K2 for redrawing stages
Relative materials thickness s/D %
Mn 0.45 0.48 0.5 0.52 0.55 0.60 0.65 0.70 0.75 0.80
5.0 0.85 0.70 0.60 0.50 0.42 0.32 0.28 0.20 0.15 0.12 2.0 1.1 0.90 0.75 0.60 0.52 0.42 0.32 0.25 0.20 0.14 1.2 1.10 0.90 0.75 0.62 0.52 0.42 0.30 0.25 0.16 0.8 1.00 0.82 0.70 0.57 0.46 0.35 0.27 0.18 0.5 1.10 0.90 0.76 0.63 0.50 0.40 0.30 0.20 0.2 1.00 0.85 0.70 0.56 0.44 0.33 0.23 0.1 1.10 1.00 0.82 0.68 0.55 0.40 0.30
DR. Ramadan EL-Gamsy
![Page 27: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/27.jpg)
Die Radius
Die radius in deep drawing for first stage
Punch radius.
Stage S/D % 2.0…………1.0 1.0……..0.3 0.3…….0.1
(6…..8)S (8…..10)S (10…..15)S
S/D % > 0.6 0.6…..0.3 < 0.3
Rpunch = Rdie Rpunch = 1.5 Rdie Rpunch = 2 Rdie
DR. Ramadan EL-Gamsy
![Page 28: Deep Drawing Lec 1](https://reader034.fdocuments.net/reader034/viewer/2022042505/563db970550346aa9a9d5215/html5/thumbnails/28.jpg)
Drawing with ironing
DR. Ramadan EL-Gamsy