Deep drawing is one of widely used sheet metal working process in industries to produce cup shaped components at a very high rate. With 100 years and 4 generations of experience, amalco offers design and engineering support for customers who need to manufacture deep drawn and hydroformed metal products and parts. An external force on a flat metal sheet makes this plastic deformation. Deep drawing dd is one of the sheet metal forming processes widely used in automobile. The stress in the flange region during the deep drawing process is a combination of radial tensile drawing stress and a tangential compressive stress hoop stress. Deep drawing is the manufacturing process of forming sheet metal stock, called blanks, into geometrical or irregular shapes that are more than half their diameters in depth. In order to address these problems, a dummy block is used between the ram. The phenomenon of wrinkling flange instability is specific to the process of deepdrawing. It is thus a shape transformation process with material retention. A fusion weld is a weld in which the metal surfaces have been melted in. Defects in metal forming processes and their remedies. Simulation of defects in microdeep drawing of an aluminium alloy foil. Applied for cylindrical cup manufacturing by multistage deep. From this process, complex shapes can be manufactured with fewer defects.
The deep drawing process is a forming process which occurs under a combination of tensile and compressive conditions. Cu and sn are used as lubricants for high strength materials. Oils and greases for wire drawing mulsifiable oils for wet wire drawing soap for dry drawing. Publishers pdf, also known as version of record includes final page, issue and. The main reason to carry out such a process is taking the advantages of different materials, such as high strength, low density and corrosion resistibility, at the same time and in a single component. Benefits of deep drawn metals the deep drawing process is especially beneficial when producing high volumes of products, as unit cost decreases as unit count increases. By analyzing these parameters, the defects like wrinkling, tearing, earing is reduced and also we can get the good quality product. If you are in need of a large order, then going for this process seems like the right choice.
Journal of engineering sciences, assiut university, faculty of engineering, vol. Abstract deep drawing is one of the most important processes for forming sheet metal parts. Deep drawing is one of the most widely used processes in sheet metal forming. Deep drawing deep drawing is defined as a tensilecompressive sheet forming process in which a plane blank is formed into a hollow part open on one side or an open hollow part is formed into another hollow part with a smaller crosssection. The schematic drawing of the conventional deep drawing process is depicted in figure 6. Deep drawing operation is based on manufacturing engineering parts with particular shapes through major plastic deformation of completely flat metal sheets. Deep drawing deep drawing deep drawing is defined as a. Defects that occur in metal drawing manufacture are similar to those that occur while manufacturing by extrusion. The geometry parameters used in deep drawing process are mentioned below. The workpiece material used in a deep drawing process is anisotropic in nature, due to a prior thermomechanical treatment. Thats one of several reasons its been a trusted form of metalwork for hundreds of years. Friction in deep drawing technische universiteit eindhoven. Deep drawing is a sheet metal forming process which is widely used in manufacturing parts for automobile and air craft industries.
In this paper, the mechanism of deformation, effect of the geometrical parameters involved and the defects encountered in the process are presented and discussed. The effect of using nonuniform blank holder force in deep. Metal forming using deep drawing has its advantages and disadvantages. The deep drawing of cylindrical cups has also been extensively studied see e. Study of earing defect during deep drawing process with. On classical tool design without drawbeads flow of blank material is influenced by blank size and shape, drawing tool. The pros and cons of deep drawing age of innovation. Instability in the work piece, also called wrinkling of the walls.
Deep drawing metal parts fabrication american aluminum. The prediction of these type of defects, as well as formability, are. In general, a metal forming process is called deep drawing if the depth of the drawn part exceeds its diameter. It is widely used for mass production of cup shapes in automobile, aerospace and packaging industries. Large set of manufacturing processes in which the material is. Rolling defects and remedies pdf these shapes are further processed through hot rolling, forging or extrusion, to. The deep drawing process involves a great deal of sliding of the sheet material along the tools. Our team is ready to help you solve design challenges and answer your hydroforming process and deep drawing process questions. Mold characteristics and friction play a critical roll in the process. A size effect, more specific a density effect, explains the changes in forming behavior of foils with respect to the forming limit, denoted by the limiting drawing ratio. For general deep drawing, operations, most people define the defects as that block which can be deformed into a cylindrical cup with either a uniform flange or. One of the primary defects that occur in deep drawing operations is the wrinkling of sheet metal material. However, if you have a small even medium sized order, then thinking about a new technique might be a better idea.
In general, the deep drawing method is highly valuable for large quantity or long run production orders for multiple reasons. A variety of metals can be deep drawn, including aluminum, stainless steel, aluminized steel, cold rolled steel. Effects on the deep drawing diagram in micro forming. Principally on sheet metal forming defects as described in. Simulation studies on deep drawing process for the. Modelling of contact and friction in deep drawing processes. Pdf deep drawing mechanism, parameters, defects and. Shallow drawing is defined as that where the cup height is less than half the diameter. Effects of various parameters in deep drawing process over. Deep drawing mechanism, parameters, defects and recent results. Finite element simulation of earing defect in deep drawing. The process is considered deep drawing as the depth of the drawn part exceeds its diameter. Prevent the failure caused by the defect in tooling design. Deep drawing process is a significant metal forming process used in the sheet metal forming operations.
The phenomenon of wrinkling flange instability is specific to the process of deep drawing. Wire drawing process hot rolled rod pickling, descaling lubricating drawing\ remove scale causing surface defects. Optimization of deep drawing process for circular cup forming. Sheet metal drawing is a more complex operation than cutting or bending operation, and more things can go wrong during sheet metal drawing. Or conversion coating such as sulphates or oxalates. Preventing wrinkles in the deep drawing process thomasnet.
Deep drawing is a sheet metal forming process that involves complex material flow and force distributions. Additionally, strategies are proposed to help mitigate common problems in deep drawing. Ghosh department of engineering, university of cambridge, cambridge, england received 23. Parts of various geometric and sizes are made by drawing operation, two extreme example being bottle caps, automobiles panels etc. In this paper, the effects of several parameters on the deep drawing process of laminated sheets are comprehensively studied. Effect of various parameters on the wrinkling in deep. Advantages, disadvantages of deep drawing and stamping. Theoretical and experimental analysis of deep drawing. Blankingblanking is the process ofcutting the initial sheet coil stockinto round or shaped flatsrequired for deep drawing. Drawing ratio, punch corner radius, punch speed etc. Effects of different parameters on deep drawing process ijert. Following is a list of common defects during sheet metal operation, with sketches are shown in figure 1. Deep drawing can achieve up to 43% reduction on a metal blank, and multiple successive deep draws can be used to achieve part size or shape requirements. How deep can metal be drawn deep drawing, hydroforming.
Deep drawing process the deep drawing is one of the commonly applied methods in sheet metal forming. In sheet metal forming smf processes, such as deep drawing, friction plays an important role. The limits of the processing window for deep drawing, collected in a deep drawing diagram, are affected by material behavior, process parameters and size effects. The manufacturing of deep, cuplike products from thin sheet metal is known as deep drawing. Earing is one of the major defects observed in a deep drawing process. Defects in deep drawing deep drawing is a more complex operation and more things can go wrong. A number of defects can occur in a sheet metal drawn product. Effect of process parameters on spring back in deep. Pdf design and analysis of deep drawing process on. Anshul bindal econtent for aktu manufacturing technology1 duration.
Failure of sheet metal parts during deep drawing processes usually takes place in the form of wrinkling or tearing. Under certain conditions, this sliding will cause friction between the tools and the material. Deep drawing is an extensively used press working process since it eliminates expensive machining and welding operations and enables the production of components at a very high rate. The faying surfaces are the contacting surfaces in a welded joint. Deep drawing of 304 l steel sheet using vegetable oils as forming lubricants y.
Jayaram2 1research scholar, department of mechanical engineering,malnad college of engineering, hassan karnataka state, india. Controlling metal flow is essential in preventing defects. In rolling the crystals get elongated in the rolling direction. The four major defects which can occur during deep drawing are fracture, wrinkling, earing and spring back. Analysis of optimization of blank holding force in deep. The following is a list of common problems that may be encountered when deep drawing cyclindrical cups. Blank shape optimization in deep drawing process to minimize earring defect indian j. Manufacturing by multistage deep drawing with simultaneous ironing. It is shown that it occurs in so called tiffany structures. Apart from its use in many other sectors, it is applied in the automotive industry for the manufacturing of car body parts. In the deep drawing process, deformation defects such as fracture and wrinkling have been found due to large deformation. In deep drawing process the main objectives are to obtain defect less or.
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