MFDP2 - L04 - Deep Drawing and Stretch Drawing - ENIM 2021-22

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Mise en forme par déformation plastique 2

MECA 2

Lecture 04: Deep drawing and stretch forming

2021-22

Prof. Dr.-Ing. habil. Sami Chatti

Content

L02 – Deep drawing and stretch forming


Deep drawing
Principle and process parameters
Stresses and process forces
Process limits
Drawing ratio
Applications
Machines

Stretch forming
Principle and process parameters
Applications

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Comparison deep drawing vs. stretch forming

Deep drawing Stretch forming

Tensile-Compression stress in No wrinkles (pure tensile stress)


flange area (risk of wrinkles) Thickness reduction
Standard process for large Low springback
production scale Oversize parts
Constant sheet thickness is
aimed

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Content

L02 – Deep drawing and stretch forming


Deep drawing
Principle and process parameters
Stresses and process forces
Process limits
Drawing ratio
Applications
Machines

Stretch forming
Principle and process parameters
Applications

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Principle of deep drawing
FP

Punch

FBH FBH Blankholder

Sheet

Die

Definition according to DIN 8584:


Deep drawing belongs to the process of tensile-compressive forming of a sheet metal blank
(blank, circular blank) into a hollow part or of a hollow part to a hollow part with a smaller
circumference without an intended change of the sheet thickness

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Deep drawing – process

Insert blank

Blankholder closing Punch


Blankholder
Punch in contact
with sheet Blank
Die
Deep drawing

Ejection of sheet
metal part
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Deep drawing – process

Insert blank

Blankholder closing
Punch
Blankholder
Punch in contact
with sheet Blank
Die
Deep drawing

Ejection of sheet
metal part
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Deep drawing – process

Insert blank

Blankholder closing Punch


Blankholder
Punch in contact
with sheet Blank
Die
Deep drawing

Ejection of sheet
metal part
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Deep drawing – process

Insert blank

Blankholder closing
Punch
Blankholder
Punch in contact
with sheet Blank
Die
Deep drawing

Ejection of sheet
metal part
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Deep drawing – process

Insert blank

Blankholder closing

Punch in contact
with sheet

Deep drawing

Ejection of sheet
metal part
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Process parameters deep drawing
Blankholder

FP
FBH
• Initial diameter of blank d0 Die

• Actual blank diameter d Punch

• Punch diameter dp rp
rd
• Punch radius rp
dp
• Die diameter dd dd
• Die radius rd d
d0
• Punch force FP
• Blankholder force FBH
• Drawing ratio:
• Clearance u = (dd – dp)/2 = 1.2...1.35 t0
d0
• Sheet thickness t0 0 
dp

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Dimensioning of (circular) blanks for round


deep drawing components

2
D0  2d1  4h 2

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Content

L02 – Deep drawing and stretch forming


Deep drawing
Principle and process parameters
Stresses and process forces
Process limits
Drawing ratio
Applications
Machines

Stretch forming
Principle and process parameters
Applications

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Stresses in deep drawing

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Deep drawing according to DIN 8587

Main group 2

Forming

Subgroup 2.1 Subgroup 2.2 Subgroup 2.3 Subgroup 2.4 Subgroup 2.5
Tensile-
Compressive Tensile Bend Shear
compressive
forming forming forming forming
forming
DIN 8583 DIN 8584 DIN 8585 DIN 8586 DIN 8587

Subgroup 2.2.1 Subgroup 2.2.2 Subgroup 2.2.3 Subgroup 2.2.4 Subgroup 2.2.5

Stripping Deep drawing Spinning Flanging Wrinkle bulging


DIN 8584 sheet 2 DIN 8584 sheet 3 DIN 8584 sheet 4 DIN 8584 sheet 5 DIN 8584 sheet 6

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Forming area of a deep drawing part with


rotational symmetry

Flange
Deformation occurs in the flange area

s0

Wall

Bottom
s1 s 0

s1 s 0

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Stresses during deep drawing

Flange
s Z  s id  s B  s F

Ideal stress (proportion) Wall

s id  1 .1  k fm  ln d
DP Bottom
Bending (proportion) dx
s B  f (k f , s 0 , rM ) st
x
Friction force (proportion)
s F  s FN  s FZ sr + sr
dj
ds r
between tool and blank
DP
s FN  f (m , s N ) RP =
2 st
due to the deflection at the die radius
p
R=D
2
m
s FZ  e 2  f (s id , s B , s FN )

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Drawing force

second peak if
clearance too small

r '0r' 0,0.77
77  r0r
0 0

 
FP  Fid  FR  Fbending   e
 μ Ø: cup angle
 
ideal force flange friction     die-ring friction
 bending/unbending 

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Blankholder force

The blankholder force to prevent wrinkling


corresponds to an average pressure on the
flange of 1 to 2 % of the flow stress. Letting
this fraction to be l, we get:

FBH  l  k f  p ( r0 )  ( rm ) 
2 2

 

Since the blankholder force is usually


constant:

FBH  l  k f  p ( r0 )  ( rm ) 
2 2

r0  
where 0.01  l  0.02
𝑟 = 𝑟 + 𝑠 /2
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Total drawing force

   r0  m  FBH k fm ,die-ring  s0  μ 


2

FP  2p rm    k fm ,flange  s0 ln       e   sin 


   rm  p  r0 2  rfd  s0  

 r 
ln  0 
 rm 
s fm 𝑟 : 𝐷𝑖𝑒 𝑝𝑟𝑜𝑓𝑖𝑙𝑒 𝑟𝑎𝑑𝑖𝑢𝑠
∅: Cup angle (e.g. )
𝛼: Die angle (e.g. )

r0  0.77  r0

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Deep drawing component with and without
earing formation

Source: Deutsches Kupferinstitut


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Determination of anisotropies in thin sheet


metal
Vertical anisotropy Horizontal anisotropy:
rm = 1/4 ( r0 + r90 + 2 r45 ) r = 1/2 ( r0 + r 90 - 2 r45 )
For deep drawing sheet metals a For deep drawing sheet metals a
value as high as possible is desired value as small as possible is desired

Determination of r -value:
sampling for tension test
0°, 45° and 90° to the
rolling direction

Rolling direction

Effect on deep drawing:

Large
Largelevel
levelanisotropy
anisotropy= =large
largeearing
earingformation
formation

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Example 1: Punch force

1) A non-hardening aluminum blank of 120 mm diameter and 1.2 mm


thickness has a flow stress of 300 MPa. It is deep drawn to a
cylindrical cup of 60 mm mid-wall diameter. What is the final height of
the product? (assume constant material thickness)

2) For the deep drawing process mentioned above, the blankholder


force is 40 kN and the friction coefficient is 0.1. What is the value of
the maximum punch force? (Use the equation given below).

𝑟 μ𝐹 μπ
𝐹 = 2π 𝑟 σ 𝑡 ln + exp
𝑟 π𝑟 2

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Solution example 1

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Content

L02 – Deep drawing and stretch forming


Deep drawing
Principle and process parameters
Stresses and process forces
Process limits
Drawing ratio
Applications
Machines

Stretch forming
Principle and process parameters
Applications

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Failure modes (1)

Wrinkles of 1st order


Description: Undesirable wrinkling which can occur in
deep drawing in that part of the blank which hast not
entered the drawing die

Possible counter measures:


Increase blankholder force
Increase friction in flange area
Wrinkles of 2nd order
Description: Undesirable wrinkling in that part of the wall of
a drawn shape which has passed over the radius of the die

Possible counter measures:


Increase blankholder force
Increase blank diameter
Use of drawbeads
Decrease die clearance
Decrease die and punch radii
Source: CIRP dictionary

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Failure modes (2)

Bottom tear
Description: A split or failure near the bottom portion of a
drawn cup

Possible counter measures:


Reduce blankholder force
Increase die and / or punch radii
Increase of die clearance

Earing
Description: A regular variation in length of a cup or
ironed part which results from the anisotropic properties
of the initial workpiece

Possible counter measures:


Use of isotropic material

Source: CIRP dictionary

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Failure modes (3)

Spring back
Description: The amount by which a workpiece reverts
towards its original shape after removal of forming load

Possible counter measures:


Adjustment of blankholder force
Modification of tool geometry
Modification of part design
Source: CIRP dictionary

Source: Simon, H.: Rechnergestützte Ziehteilauslegung mit elementaren Berechnungs-


Methoden, Universtät Hannover, Dr,-Ing. Dissertation, 1989
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Influence of geometrical parameters

Die radius

Radius too small  Bottom tear


Fp
FBH
Radius too large  Reduction of flange area

Blankholder
Punch radius Punch

Radius too small  Punch cuts the sheet Die

Die clearance

Die clearance too large  Cup is widened  Wrinkles of 2nd order


Die clearance too small  Iroining, increased punch force; bottom tear; galling possible

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Design of Deep Drawing Tools

Die clearance u z
uz = 1.2t ......1.35t t: blank thickness
(According to Lange)

Depth of draw hz Punch Blankholder


F
BH
hz is limited by maximum drawing ratio

F
P
Punch radius rP
Die
rP > r
D

r rP
Die radius rD D
0.04 D0
rP  (50  D0  DP )t
DP100 2
h
D z
t Blank thickness P

100 maximum drawing ratio u
z

(According to Romanowski)

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Variables in deep drawing -blankholder force-

Blankholder force too high

FP

FBH

Blankholder force too low Adequate blankholder force

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Process limits of deep drawing process

F
BHmax

Tears
BH
Blankholder force F

Working area

Wrinkles

Depth of draw h

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Process control of the deep drawing process

Disturbance variable
Characteristics of semifinished products
Lubricant (amount, type, distribution,...)
Tool characteristics (surface, wearout,...)

Deep drawing process Result

Control manipulated
variable Reference variable
Blankholder force Drawing force
(global or for several Height of wrinkles
force transmission
Flange feed-in
points)
Controller Friction force
(dependent on the displacement
of the punch)

Strategy /
set values
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Content

L02 – Deep drawing and stretch forming


Deep drawing
Principle and process parameters
Stresses and process forces
Process limits
Drawing ratio
Applications
Machines

Stretch forming
Principle and process parameters
Applications

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Drawing ratio β in first draw and second draw

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Influence of the punch diameter on the


maximum drawing ratio
2.2

2.1
St 1403, Ms 63B, Ns 180
Maximum drawing ratio  0,max

St 1203, Ms 63A
St 1303
2.0

1.9

1.8
AL 99.5
AlMn

1.7
0 100 200 300 400
Punch diameter DP
t0

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Increasing the drawing ratio (1)

Direct successive drawing Reverse drawing

Outer surface remains outer Inner surface from the first drawing
surface of the formed cup becomes the outer surface in the second
drawing

N. Bay (2002)

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Increasing the drawing ratio (2)

Conventional Increased drawing ratio

N. Bay (2002)

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Deep drawing and Ironing

VAW Aluminium AG (2001)

Ironing process: force at end cross section:

 2m m  tan  
Ftotal  A1  k fm 1    jmax 
 sin 2 tan   2 

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Example 2: Drawing ratio

A cylindrical cup as shown in the figure is manufactured from St 1303


steel blank. The permissible draw ratio for this material is 2.05.

Determine:
(1) the blank diameter d0.
(2) the actual drawing ratio.
(3) the minimum number of draws required in order to produce the part.

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Solution example 2: Drawing ratio

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Example 3: Process design

From a 1 mm thick blank of sheet metal material number 1.0338 (St


14) a hollow cylindrical part with a diameter of 45 mm and a can body
height of 90 mm is to be drawn. The limiting draw ratio βmax of the
material is 2.

1) Calculate the initial diameter D of the circular blank.


2) Calculate the total drawing ratio βtot.
3) If βtot is greater than the limiting drawing ratio βmax, several
drawing operations are needed. In order to have a robust and
reproducible production sequence, the maximum permitted
drawing ratios should not be fully utilized. Design a process with
three operations whereby β1 may have a maximum value close to
2, and all following β values are less than 1.3. Determine the
values of the punch diameters.
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Solution example 3

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Content

L02 – Deep drawing and stretch forming


Deep drawing
Principle and process parameters
Stresses and process forces
Process limits
Drawing ratio
Applications
Machines

Stretch forming
Principle and process parameters
Applications

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Movie: Deep Drawing

Principle: Real Process:


FP

FBH FBH

Placing the blank

Closing the blankholder

Movement of the punch

Deep Drawing

Ejection of the workpiece

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Drawbeads for drawing irregular parts

Drawbeads
• Drawbeads are used for parts of a
plane, rectangular, irregular or
complex geometry
• In general, drawbeads are placed
at side walls and are used to slow
down the material flow
• In corner radii the material flow is
undisturbed

Blankholder Punch

Drawbeads
Die

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Deep drawing: applications in automotive sector

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Variation of steel material used in the car body

60
Mild steels, Structural steels

50 Isotropic steels
Total elongation A 80 in %

Higher-strength IF-steels
40 Dual-phase steels (DP)
TRIP steels
TRIP 1000
30

20 Bake-hardening
steels DP800 / 1000
Work hardening Hot-formed steels
10 Micro-alloyed
steels
steels Complexphase
steels (CP) CP1000
0
200 400 600 800 1000 1200
Einleitung

Tensile strength R m in MPa


(Source: ThyssenKrupp Steel Europe)

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Material used in the car body – Mercedes C-class
Mild steel
High strength steel
Highest strength steel
Ultra high strength steel
Hot-formed steel
Aluminium
Plastic

Highest strength steel (11%)

High strength Ultra high strength steel (3 %)


steel (50%)
Hot-formed steel 6%

Aluminium (3%)
Source: Mercedes-Benz
Mild steel Plastic (2%)
Source: ATZ extra „Die neue C-Klasse von Mercedes-Benz“, April 2007 (25%)
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Material used in the car body – Volkswagen VW up!


Hot-formed steel
Ultra high Mild steel
strength steel

Highest
strength steel High strength steel

Source: ATZ extra „Der neue VW up!“, September 2011

Source: Volkswagen

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Deep drawing: applications in the household

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Content

L02 – Deep drawing and stretch forming


Deep drawing
Principle and process parameters
Stresses and process forces
Process limits
Drawing ratio
Applications
Machines

Stretch forming
Principle and process parameters
Applications

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Deep drawing of large sheet metal components:
Tools and large panel transfer press

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Double action hydraulic press

Slide cylinder
Press crown

Tie rod

Die

Punch
Slide cushion

Blankholder

Lifting cylinder
Draw cushion
Draw cushion
cylinder

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Principle: double action press

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Principle: double action press

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Principle: double action press

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Principle: double action press

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Principle: double action press

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Principle: double action press

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Setup of a hybrid press

Clamp set for stroke adjustment Eccentric shaft

Feed drive Clutch-brake


combination with
compact drive

Hydraulic accumulator
Slide for bottom side
counter- Compressed air
balance accumulator for
Hydraulic slide counterbalance
cylinder mechanically actuated
top slide
Bed plate Hydraulic actuated
bottom slide
Bed plate
shift device Position sensing system
for the slide

Hydraulic Scrap chute


draw cushion
Damping element

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Triple action hydraulic press


Hydraulic in
block construction
Main motor
Slide cylinder

Blankholder
cylinder
Main pump

Blankholder
guide

Adjustment of
depth of draw
Pressure adjustment
Limit switch

Draw cushion
guide
Draw cushion
plate

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Principle: triple action press

Hydraulic in
block construction
Main motor
Slide cylinder

Blankholder
cylinder
Main pump

Blankholder
guide

Adjustment of
depth of draw
Pressure adjustment
Limit switch

Draw cushion
guide
Draw cushion
plate

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Principle: triple action press


Hydraulic in
block construction
Main motor
Slide cylinder

Blankholder
cylinder
Main pump

Blankholder
guide

Adjustment of
depth of draw
Pressure adjustment
Limit switch

Draw cushion
guide
Draw cushion
plate

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Principle: triple action press

Hydraulic in
block construction
Main motor
Slide cylinder

Blankholder
cylinder
Main pump

Blankholder
guide

Adjustment of
depth of draw
Pressure adjustment
Limit switch

Draw cushion
guide
Draw cushion
plate

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Principle: triple action press

Hydraulic in
block construction
Main motor
Slide cylinder

Blankholder
cylinder
Main pump

Blankholder
guide

Adjustment of
depth of draw
Pressure adjustment
Limit switch

Draw cushion
guide
Draw cushion
plate

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Principle: triple action press

Hydraulic in
block construction
Main motor
Slide cylinder

Blankholder
cylinder
Main pump

Blankholder
guide

Adjustment of
depth of draw
Pressure adjustment
Limit switch

Draw cushion
guide
Draw cushion
plate

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Principle: triple action press

Hydraulic in
block construction
Main motor
Slide cylinder

Blankholder
cylinder
Main pump

Blankholder
guide

Adjustment of
depth of draw
Pressure adjustment
Limit switch

Draw cushion
guide
Draw cushion
plate

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Principle: triple action press

Hydraulic in
block construction
Main motor
Slide cylinder

Blankholder
cylinder
Main pump

Blankholder
guide

Adjustment of
depth of draw
Pressure adjustment
Limit switch

Draw cushion
guide
Draw cushion
plate

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Classification of deep drawing presses according to


the amount of degrees of freedom
Classification of deep drawing presses according to the amount of degrees of freedom

Corresponding to the amount of necessary degrees of freedom (acting axis) the following presses are
used:
- Single action press (movement of the main slide)
- Double action press (movement of main and blank holder slide or main slide and die
cushion)
- Triple action press (movement of main and blank holder slide and die cushion)

Classification of deep drawing presses according to the kind of movement generation

- Displacement-related (crank, eccentric, knuckle joint press) and


- Force-related (hydraulic) press

Advantages of hydraulic presses disadvantages of hydraulic presses


High nominal forces can be obtained lower number of strokes than with mechanical
presses
High nominal forces are available during the high energy consumption
whole forming procedure
precisely adjustable and controllable force and speed
simple and stepless adjustability of stroke and
dead centres of the slide
easier automation
protection against overloads
possibility to interrupt the slide stroke
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Content

L02 – Deep drawing and stretch forming


Deep drawing
Principle and process parameters
Stresses and process forces
Process limits
Drawing ratio
Blank
Case studies
Applications

Stretch forming
Principle and process parameters
Applications
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Definition of stretch forming

Definition according to DIN 8585:


Stretch forming is the forming of a sheet blank with a rigid
(one-piece) punch, whereby the blank is rigidly clamped at
the edges. The blank can be clamped between rigid tools,
corresponding to the upper and lower drawing frames of the
conventional tools, or be clamped in gripping jaws.

Types of Stretch Forming


Simple stretch forming
Tangential stretch forming
Stretch forming according to Cyril-Bath
Multi-sided stretch forming

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Stretch forming – process principle

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Stretch forming – process principle

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Application example

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Film: Stretch forming

Process principle: Real Process: Airplane side wall

Insert blank

Close collets

Move punch

Stretch forming

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Stretch forming according to DIN 8585

Main Group 2

Forming

Subgroup 2.1 Subgroup 2.2 Subgroup 2.3 Subgroup 2.4 Subgroup 2.5
Tensile-
Compressive- Tensile- Bend Shear
compressive
forming forming forming forming
forming
DIN 8583 DIN 8584 DIN 8585 DIN 8586 DIN 8587

Subgroup 2.3.1 Subgroup 2.3.2 Subgroup 2.3.3


Extending Expanding Stretch identing
DIN 8585 DIN 8585 DIN 8585

Subgroup Subgroup
2.3.3.1.1.1 2.3.3.1.1.2
Stretch drawing Embossing
DIN 8585 DIN 8585

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Deformation area during stretch forming

Plastic deformation only in


the inner area of the blank

F
Punching force F
s0
F
max
s1< s0
Displacement of the punch

Inhibit the flange feed-in


e.g. with the help of clamping
elements in the tool

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Content

L02 – Deep drawing and stretch forming


Deep drawing
Principle and process parameters
Stresses and process forces
Process limits
Drawing ratio
Blank
Case studies
Applications

Stretch forming
Principle and process parameters
Applications
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Simple stretch forming

Punch

Source: Müller-Weingarten Co.

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Example of simple stretch forming

Airplane wings

Stretch forming at TAI

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Tangential stretch forming

Punch

Source: Müller-Weingarten Co.

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Flexible stretch forming

Punch

Four gripper stretch


forming machine

Source: IFU Stuttgart

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Surface failure by stretch forming


Reason: Yield-Point Elongation

Stretch formed part with Lueder‘s bands

Source: S. Kalpakjian

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Film: The crossbar transfer press by Schuler

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Appendix: English for Production Engineers

English Français English Français


Emboutissage
Deep Drawing Earing Formation d'oreilles
profond
Rapport
Punch Poinçon Drawing Ratio
d’emboutissage
Blankholder/Binder Serre-flan Limiting Drawing Rapport limite
Die Matrice Ratio (LDR) d’emboutissage
Profondeur
Die Radius Rayon de matrice Depth of Draw
d'emboutissage
Clearance Jeu d’emboutissage Wall (of a cup) Paroi
Drawbead Jonc de retenue Flange (of a cup) Collerette
Formage par
Fracture Fracture Stretch forming
extension
Fracture à la base de
Bottom Tear
la coupelle
Wrinkling Plissement

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