Deep drawing is a manufacturing process that is used extensively in the forming of sheet metal into cup or box like structures. Deep drawing metal stamping manufacturing technology is defined as the stretching of sheet metal stock, commonly referred to as a blank, around a plug. Types of press working or sheet metal operations pdf. Din 8584 deep drawing processes are divided into three. Sheet metal material selection process can be divided into two parts.
Simulation of aluminium sheet metal deep drawing at elevated. Design and analysis of a deep drawing and in process. Deep drawing is a sheet metal forming process that involves complex material flow and force distributions. Metal sheet blank holder ring on cushion compressible cushion sheet metal stamping drawing car industry 90million cars and commercial vehicles produced worldwide in 2014. Very complex parts can be achieved using deep drawing. Drawing forming a sheet into a hollow or concave shape. Aluminium sheet metal is well known for its ability to improve the strength to weight ratio of lightweight structures.
Sheet metal is one of the very convenient ways that is used in metal working and it can be mended and cut into various shapes and dimensions. This mode of deformation is found mostly on smooth bottoms of shallow parts and in hydroforming processes. Sheet metal material selection process is a crucial part of product design. Sheet metal material selection material type and its. Yieldpoint elongation lueders bands on lowcarbon steels and almg alloys. Sep 05, 2017 drawing can be defined as a forming process in which the flow of metal into a cavity or over a post is controlled. Apr 15, 2017 sheet metal drawing is a more complex operation than cutting or bending operation, and more things can go wrong during sheet metal drawing. Pdf this paper deals with the deep drawing of metal cups using the marform process. Deep drawing force calculator calculate the required force to deep draw a piece of sheet metal based on the drawing ratio, sheet thickness, and the ultimate tensile strength of the material. While its true that a lot of the parts including automobile hoods and doors are made using the process of metal flow and stretch known as stretch drawing, deep draw. A flat sheet metal blank is formed into a hollow body open on one side or a hollow body is formed into a hollow body with a smaller crosssection. The design as well as the subsequent analysis of a deep drawing and inprocess electromagnetic sheet metal forming calibration will be described in this paper.
Deep drawing is a process of converting metal sheet into cylindrical or box shaped structure with or without changing its length and thickness. Jun 16, 2010 deep drawing often requires more than one drawing process. Deep drawing dd is one of the sheet metal forming processes widely used in automobile, aerospace, electronics and allied industries to produce the hollow parts. The deep drawing process is a forming process which occurs under a combination of tensile and compressive conditions. Shearing not a forming process but a cutting process. Pdf thinning and residual stresses of sheet metal in the. Metal casting metal forming metal rolling metal forging metal extrusion metal drawing powder processes ironing of sheet metal ironing of sheet metal is a manufacturing process that is mostly used to achieve a uniform wall thickness in deep drawings. Deep drawing is affected by many factors such as material properties, tool geometry, lubrication etc.
Mar 06, 20 sheet metalworkingforming on metal sheets, strips, and coils. In sheet metal forming practice, we distinguish five basic modes of deformation. A number of defects can occur in a sheet metal drawn product. This process transforms flat sheet metal, or blank, into a hollow vessel that may be cylindrical or boxshaped, with straight or tapered sides or a combination of straight, tapered and curved sides. Pots and pans for cooking, containers, sinks, automobile parts, such as panels and gas tanks, are among a few of the items manufactured by sheet metal deep drawing. This cup can then be further processed, for example by an additional drawing, reverse drawing, ironing or extrusion process. Like a single drawing process, redrawing uses both metal flow and tension to achieve the. The literature tends to concentrate on the study of deformations, stresses, and forces prevailing during the operation.
Rao, manufacturing technology, tata mcgraw hill, 1998. Sheetmetal forming processes are widely used in the manufacturing industry. The draw reduction process frequently is used to produce very deep geometry. Amazingly complex shapes can be generated using this process, but a good metal stamping design will take the process and material into consideration. The metal deep drawing process is a effective method of manufacturing of cups, cans and other similar deep drawing products. Deep drawing is one of the most important processes for forming sheets metal parts. Therefore the first step in any sheet metal process is to cut the correct shape and sized blankfrom larger sheet. Analysis of deep drawing of sheet metal using the marform process article pdf available in international journal of advanced manufacturing technology 5958 march 2012 with 1,154 reads. The punchdie clearance is slightly larger than the thickness of the sheet metal to be deep drawn. The sheet metal process are bending, embossing, coining, spinning, stretch forming and deep drawing. Deep drawing uses radial tensiontangential compression to shape the metal. It is thus a shape transformation process with material retention.
In this article we mainly focus on sheet metal cutting operations and other two we will discuss into upcoming articles. The process is considered deep drawing when the depth of the drawn part exceeds its diameter. That is, the work of perforating, forming and blanking is done by the up and down movement of press equipment. The drawing ratio is a measure of the severity of the drawing operation and is the ratio of the initial blank diameter to the punch diameter. Analysis of deep drawing process for stainless steel micro. Deep drawing is a common process in industry for manufacturing products from sheet metals. Thinning and residual stresses of sheet metal in the deep. This paper introduces deep drawing of aluminium sheet metal at elevated temperatures, a corresponding simulation method, a characteristic process and its optimization. Perhaps one of the biggest misconceptions about deep drawing is that the metal is stretched into the part geometry. Sheetmetal characteristics elongation the capability of the sheet metal to stretch without necking and failure. May 07, 2017 mainly sheet metal process can be divided into three types. In this article we will discuss sheetmetal materials their advantages and limitations. This mode is typical the material flow from the flange towards the.
Design for deep drawing sheet metal stamping engineers edge. The developed system is based on the integration between computer aided process planning in sheet metal drawn parts capp, and. Typically, sheets of metal are sold as flat, rectangular sheets of standard size. Luders bands can be eliminated by coldrolling the thickness by 0. Lightweight design is essential for an economic and environmentally friendly vehicle. Metal deep drawing process of sheet metal forming techminy. The first one is sheet metal cutting, second one is sheet metal bending or forming and the last one is known as deep drawing. In this way the formability of aluminium sheet metal can be improved significantly. Pdf process simulation of aluminium sheet metal deep. Metal deep drawing process of sheet metal forming metal deep drawing process. Introduction deep drawing operation is frequently used in the. Al1050, sheet metal forming, multistage deep drawing. It is used widely for mass production of hollow shapes in the packing.
Sheet metal forming processes ksu college of engineering ie department 3 definition. Bending straining of a metal sheet to form an angle bend. Jun 02, 2011 cookware deep drawing hydraulic press 315 tons aluminum cooking pot with automatic feeder duration. Thinning and residual stresses of sheet metal in the deep drawing process. The manufacturing of deep, cuplike products from thin sheet metal is known as deep drawing. Pdf analysis of deep drawing of sheet metal using the. When more than one drawing process is used, the subsequent operations often are referred to as redrawing or reduction. With the use of the industrial manufacturing process, sheet metal is formed by working metal into flat and thin pieces. In this operation, forming of a flat metal sheet into a hollow or concave shape like a cup, is performed by stretching the metal in some regions. Paper open access related content deep drawing mechanism. This process is considered more efficient than machining because there is significantly less wastage of metal.
Sheet metal forming massachusetts institute of technology. Using this technique, higher limiting drawing ratios can be. Sheet metal stampingdrawing car industry 90million cars and. Deep drawing manufacturing process deep drawing of sheet. Variation in wall thickness often exists in parts produced by deep drawing, as discussed in the. Pdf analysis of deep drawing of sheet metal using the marform. It affects part design, cost, manufacturing process and part performance. Many cylindrical parts like metal can, pots, container for food and beverages, kitchen sinks, automobile fuel tank etc. Drawing tools nageswara rao posinasetti 1 february 6, 2012 2 february 6, 2012 sheet metal operations drawing is the process of making cups, shells, and similar articles from metal blanks. The process is widely used for producing different products such as automotive parts, cans, sinks and housing, and the application areas are getting larger every day. Following is a list of common defects during sheet metal operation, with sketches are shown in figure 1.