Objective:

The main objective of this laboratory report is study the process of deep drawing
and to evaluate the theoretical value of punch load in deep drawing, through a practical
approach. Different types of phenomena observed during the forming process are also
studied and discussed.

Summary:

The report summarises the basic concept of forming and the discussions based
on the observations after the deep drawing process in laboratory. The equipment used
for the process, procedure followed during the process is explained in brief. Various
graphs are plotted to observe variation of different parameters in the deep drawing
process and eventually its impact on the process.

Theory:

Deep drawing is a metal forming process in which sheet metal is stretched into
the desired shape. The tool pushes downward on the sheet metal, forcing it into a die
cavity in the shape of the desired part. The tensile forces applied to the sheet cause it to
plastically deform into a cup-shaped part. These parts can have a variety of cross sections
with straight, tapered, or even curved walls, but cylindrical or rectangular parts are most
common.
A set up for the deep drawing process is shown in the figure1.
Punch Centre line
Punch travel
Punch

Pressure Pressure Blank holder

b
t0

t0
h

Die
Figure 1.
As load is applied, due to compression (circumferential) the blank is drawn and its radius
is decreased from a0 to b. The material may compensate for this by thickening. However,
since the workpiece material is relatively thin, another way to relieve the circumferential
compression is by buckling or wrinkling of the workpiece. In practice this is avoided by
use of blank-holder which helps to apply just sufficient pressure so as to avoid wrinkling.
During the operation of deep drawing some processes take place which are such as pure
radial drawing between die and blank-holder, bending and sliding over die, stretching
between die and punch, bending and sliding over punch head. Within these radial
drawing thickens the metal while others thin it. The deep drawing process theory makes
some assumptions such as the workpiece thickness remains constant throughout the
operation, the punch load variation with stroke is assumed to be sinusoidal.

Experimental Procedure:

To start with the laboratory the electrical power connection to the equipment is
switched on. Then the given circular blank is placed over the punch hole. It is slightly
lubricated so as to reduce the friction. Now the upper part of the equipment is closed
properly and locked. Then the hydraulic pump is actuated and with the help of lever the
punch is actuated. Now the drawing process starts. When punch reaches maximum
stroke which is observed on the graph plotted on the equipment the process can be
stopped again by controlling lever. The maximum is noted down from the pointer reading
of the pressure gauge on the equipment. Then the upper part is opened and cup is
removed. The process is repeated for all the blanks given and relative readings are notes
as well as cup measurements are done for height, thickness etc.

Observations:

After the deep drawing operation on given blanks the cups obtained are
observed and some measurements are done. It is observed that the periphery of the cup
after deep drawing was not in a circular pattern that is the cup height is not constant. The
main reason for this is friction and the property of the material used. The properties of
material are different in different directions. The blank used for the punching was already
rolled hence the direction of flow (of the particles in the material) is in one direction. In
deep drawing process the load will act in all three directions, hence as a result of
anisotropy property of the blank material the cup after the process shows variation in
height along the periphery of the cup.
Also along the outer edge of the cup some portion is observed polished. This is
because at some stage of process the material gets accumulated at the outer periphery of
the blank. And that thickness of the blank is greater than the actual thickness of the blank
as well as greater than the gap between die and punch. This can be observed from the
graph of load Vs displacement. After reaching the maximum load there is a constant drop,
but while dropping the load is constant for some particular displacement, and this is the
amount of extra load that is required to draw the thicken material of the blank.
One of the blank drawing operations to produce cup is done without applying
holding pressure. Due to this wrinkling is observed at the periphery. It can be said from
this wrinkling effect that why holding pressure is important in the deep drawing process.
The external pressure will be high if the holding pressure is applied during deep drawing
process.
Also the operation of deep drawing is done on another set of blanks, with
another die of same dimension except with different corner radius, less than the previous
one. This is done to observe the effect of corner radius of die on the process.
After changing the die it was found that it requires high load for the process than
the load that required for a die in the previous set of deep drawing operation. After the
observation of the process on new set of blanks it can be said that if the blank diameter
increased the load required for the process also increases compared to the previous set
of operation. Also with increasing blank diameter and because the die has smaller corner
radius, the material reaches its maximum plastic form and fails during the process. This
shows that if the radius is reduced the smooth plastic flow of material is not observed
and at maximum load the material fails to bear load and thus tearing is observed. With
this modified die which is used for second set of operations only two cups are produced
properly and after second operation the third blank failed and tearing is observed.

Calculated Results and Discussions:

R=a0/b
R – draw ratio
a0 – radius of blank (mm)
b – cup radius (mm)
h=(R2-1)*b/2
......h – height of the cup

2
2 b ( σ 0 +σ ) ln ( R +1 )
P MAX=π t 0 × ×
√3 2

......PMAX – maximum load (N)

t0 – thickness of the blank (mm)
ε

:∫ σ . dε ≈ ( σ 0+ σ ) /2. ε
0
PMAX Vs Draw ratio:

Load Pmax (lbs) vs draw ratio

Load
10000
Draw Ratio Pmax(lbs)
9000
8000 1.32 4119.68
7000 1.42 5074.24
6000 1.56 5727.36
Load
5000 1.7 7636.48
4000
1.8 8490.56
3000
2000 1.93 8892.48
1000
0
1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2

Here as draw ratio increases the load required to draw the blank also increases. The load
is directly proportional to blank diameter so as the diameter increases the load to draw it
also increases.

Cup height Vs Draw ratio:

Avg cup
Draw Ratio vs Avg cup ht Draw Ratio Ht(mm)
50 1.32 14.46
45 1.42 17.96
40 1.56 24.12
35 1.7 29.28
30 1.8 36.02
Avg Ht 1.93 42.94
25
20
15
10
5
0
1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2
The graph shows that as draw ratio increases the cup height also increases. That is as the
diameter of the blank increases the height of the cup also increases. Since cup height h =
(ao2/2b) – (b/2) is directly proportional to blank radius / diameter.

Ratio of surfaces Vs Draw ratio:

Surface area of cup = (π b2) + (2π b h)

Surface area of the blank = π ao2
Ratio of surfaces = surface area of cup / surface area of blank

Ratio of surfaces vs draw ratio Surface

1.2200 Surface area area of Ratio of
1.2000 of blank cup Draw Ratio surfaces
1.1800 3846.5 4598.64 1.32 1.1955
1.1600 Ratio of surfaces 4534.16 5256.95 1.42 1.1594
1.1400
1.1200 5342.91 6187.36 1.56 1.1581
1.1000 6358.5 7042.84 1.7 1.1076
1.0800 7084.63 8179.89 1.8 1.1546
1.0600
1.2 1.4 1.6 1.8 2 8167.14 9329.34 1.93 1.1423

It is observed from the graph that with the increase in surface ratio the draw ratio
increases. But at some point there is sudden drop is observed. The reason for this drop is
due to non-uniform height of the cup which can be said on the basis that surface ratio of
the cup is directly proportional to the cup height.

Comparison of the PMAX value:

From the graph the average stress can be found, where it changes from elastic to
plastic (yield point). It is found σo = 302 KPa.
And from the graph the equation for the curve can be found. Using this equation the area
under the curve can be found.
And the area is approximately equal to a parallelogram. Hence the area found using the
equation of the curve can be equated with are of parallelogram.
 True
Natural stress
strain kPa
600

500

400

300

200

100

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
0 0
0.025 195.9 σ
y = 10308ln(x) + 58445
0.05 292.4
0.075 327.2
0.1 347.6
0.15 380.7
σo
0.2 407.8
0.25 430.4
0.3 452.4
0.35 470.1
0.4 500.4
0.45 502.1
0.5 516.4
0.55 528 Є
0.6 536.3
0.65 543.5
0.7 546.2

From graph
Y = 103083 lnX + 584450
0.7

∫ (103083lnX +584450) = area under the curve

0.25
After integration, Area = 284138 (Pa)

Area under the curve = area of the parallelogram

Using the above equation ( σ )value can be found:

(302000+σ )/2∗Є=284138

So σ = 509822.8 (Pa)

A linear equation can be found using two point form: (0, 302000) and (0.7, 509882)
And the equation of the line is Y = 296890 X + 302000
This line is approximate line for the average stress.
Using the formula for strain Є= (1/√3) ln (R 2+1/2), strain for each blank can be found.
Applying these values in the equation of line, stress value can be found.

Theoretical value of PMAX

Blank Strain Є stress σ (σ0+σ)/2 PMAX
dia(mm) (mm) (Pa) (Pa) (KN)
70 0.1878 357755.9 329877.9 22.79
77 0.2696 382041.5 342020.1 33.92
83 0.3329 400834.6 351417.3 43.04
89 0.3841 416035 359017.4 50.72
58.47
95 0.4338 430790 366395.1 7
101 0.5011 450771 376385 69.38

Empirical value of PMAX

Blank Load PMAX
dia(mm) PMAX (lbs) (KN)
70 4119.68 18.32
77 5074.24 22.57
83 5727.36 25.47
89 7636.48 33.96
95 8490.56 37.76
101 8892.48 39.55

Conclusion:

It can be concluded from the laboratory process and observations that how the
punch load in deep drawing can be predicted with approximate theory and the
phenomena observed due to variation of various parameters during the process on
various blanks are understood. The effect of variation of process parameters such as load,
draw ratio, blank diameter, cup height, ratio of surfaces is studied and the observations
including phenomena like tearing, wrinkling, ironing, earing are discussed. From the study
of the process the optimum parameters for the operation can be decided so as to avoid
these phenomena.