Experiment (5)

Deep Drawing or Shell Drawing Of Cylindrical Cup

1. Objective: For accomplish a deep drawing process and for learn and analyze the general aspects of the operation, furthermore to determine experimentally the maximum drawing force, the drawing energy, and to measure the cup height, after that to compare the results with the approximate theoretical numerical results. 2. Background: For more information about the subject of the experiments, it is recommended for the student to review section 7.12 of chapter seven of the text. 3. Theory Deep drawing is one of the most important and widely used metal forming manufacturing process that is used for Drawing of closed shapes. The depth of such shapes should be greater than the diameter of the opening (greatest surface dimension). This process first developed in the 1700s consequently has been studied extensively until has become an important metalworking process. 3.1 What is Deep Drawing A flat sheet metal blank deeply drawn by means of a punch that presses the blank into the die cavity. Schematic illustration of deep drawing process is presented in Figure 7.1, noted how does the stripper ring facilitates the removal of the formed cup from the punch.

Figure 7.1: Schematic illustration of deep

Typical parts produced are Closed Cylindrical shapes as Cans, pots and pans; rectangular container of all shapes and sizes; sinks, automobile panels, Shells, Cartridge cases; and many other similar shapes as shown in figure 7.2.

Figure 7.2: A collection of parts produced by deep

3. 2 Shallow Drawing Shallow Drawing: - is the process of drawing such products that have a depth less than the diameter of the opening (smallest surface dimension). 3. 3 Parameters of Deep Drawing To study and describe the different interaction of the parameters in deep drawing for producing a cylindrical cup the following notations have been used. Do : Diameter of a circular sheet blank. to : Thickness of the circular sheet blank. Rd : Corner radius of the die opening. : Punch diameter. D : Corner Radius of the punch. R WP : Plastic Work required for deep drawing Vo : Initial volume of blank to be drawn : Volume of drawn cup. V R : Drawing Ratio Do/Dp. : The effective strain. : Effective stress.
p
p

Figure 7.3: Variables in deep drawing of a cylindrical cup.

As shown in figure 7.3 the blank is held in place with a blank holder, or hold-down ring, with a certain force. The punch moves downward and pushes the blank into the die cavity to form a cup. Only the punch force is dependent variable, While significant independent variables are: 1. Properties of the sheet metal 2. The ratio of blank diameter to punch diameter R . 3. Sheet thickness. 4. The clearance between the punch and the die. 5. Punch and die corner radii. 6. Blank holder force. 7. Friction and lubrication at the punch, die, and workplace interfaces. 8. Speed of the punch. 3. 4 Pure Drawing Pure Drawing: - If the blank holder force is low the blank will flow freely into the die cavity -- as shown in figure 7.4-a -- by reducing the blank diameter as drawing progress. In this case the deformation of the sheet is mainly in the flange, and the work piece wall is subjected to longitudinal tensile stress, stresses increase with increasing ratio that can eventually lead to failure when the cup cannot support the load required to draw in the flange. Cup wall tends to increase in thickness as it draws into the die cavity because of the diameter reduction.
High blank holder force

Figure 7.4: Pure drawing and stretching by draw bead.

3. 5 Stretching Drawing Stretching drawing: - With a high blank holder force the blank can be prevented from flowing freely into the die cavity as in figure 7.4-b. The deformation of the sheet metal blank takes place mainly under the punch and the sheet begins to stretch. Using of draw bead can be used also as an alternative for a high blank holder force, eventually resulting in necking and tearing. Necking could be localized or distributed that depends on; the mechanical properties of sheet metal and its sensitivity to strain rate; Punch geometry and design; and finally lubrications. 3. 6 Wrinkling Wrinkling: - When there is a high clearance -- larger than the metal sheet thickness-between the punch and the die the length of the unsupported wall is significant in that it can lead to wrinkling. In figure 7.5 element A in
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Figure 7.5: Wrinkling in the unsupported region of a sheet in drawing.

the sheet is being A' pulled into the die cavity as the punch moves downward to position ,the blank is becoming smaller in diameter and the circumference at the element is also becoming smaller. At position the element is being subjected to a circumferential compressive strain and is unsupported by any tooling. Because the sheet is thin and cannot withstand compressive strains to any significant extent, it will tend to wrinkle in the unsupported area. 3. 7 Ironing Ironing: - Conversely, when the thickness of the sheet metal greater than the clearance between the punch and the die, the thickness will be reduced. This effect is known as Ironing and shown in figure 7.6. Because of volume constancy, an ironed cup will be longer than cup produced with a large clearance. Noted that ironing produced constant wall thickness and the greater the difference between clearance and sheet thickness the greater is the ironing.

Figure 6: Illustration of the ironing

4. Drawn Cup Height and Plastic Work The circular blank shown in figure 7.7 has an initial radius of ao and thickness of to it is assumed to be drawn into a cup having a uniform cylindrical wall of the same thickness, mild-wall radius b and height h . Assuming no change in metal thickness and volume after drawing then,

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VO = VC
2 .ao .to = .b 2 .to + 2 .bto .h 2 2bh = ao b 2

h=

2 1 2 a 2 b 2 b ao ( ao b 2 ) = o = 2 1 2b 2b 2b 2 b a R = o DrawingRatio b b h = R2 1 2

Figure 7.7: Circular cup to be drawn.

In deep drawing the metal is subjected to a plane radial drawing, and the three principal stresses are radial stress hoop stress

r , tangential or thickness stress t , and the circumferential or

figure 7.9.

Figure 7.9: Stresses on an element of flange.

For the distortion-energy criterion effective strain expressed as:

2 = 3 = t = 0

Hoop strain is
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 b l b = ln = Ln = ln lo a

(R

+1 2 2 = 1 ln R + 1 2 2 b
2

Substituting on the effective strain equation

2 1 R2 +1 = ln 3 3 2

the average representative stress .

2 The volume of the annulus according to figure 7.7 is V = (ao b 2 ).to ,The total plastic work required is obtained from

W P = .d .dv

Substituting for , , V and integrating we get

R2 +1 .b 2to . R 2 1 .(Y + Y f ). ln 2 2 3

5. Maximum Punch Force Drawing load values versus punch travel diagram, something like a sine curve will be obtained as in figure 7.11, this curve can be described by
P = Pmax sin

.x
h

X Figure 7.11: approximated Punch load-punch

The work done by punch is equal to the area under the curve and is
Wrk = Pmax sin
0 h

.x
h

.dx = Pmax

sin u.du = P
0

max

cos u =

cos

x
h

h 0

Wrk = Pmax .

2h

Substituting the value of h in the above equation and equating the result with equation we WP obtain,
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Pmax =

2 bt o
2 3 Yf

(Y + Y )ln R
f

+1 2

The curve may now be figured indicating the relation between maximum punch force and R for a given material. by calculating for various values of R and reading off for this value of strain from the stress-strain curve.
2bt o
2 3 (Y + Y )ln R
f 2

The maximum drawing force is, Pmax =

+1 . Another simple emprical 2

equation for calculating the maximum punch force could be express as:
D Pmax = D p t o (UTS ) o 0.7 D p

the ideal work of deformation, redundant work,friction work and , when present, the workrequired for ironing presented in figure 7.10 below:

Figure 7.10: Variation of Punch Force With Stroke in Deep Drawing.

6. Materials: A circular blank of copper is needed to run the experiment 7. Equipments: Universal testing machine equipped with pen recorder the deep drawing punch and die set and a micrometer. 8. Procedures: 1. Calibrate the universal-testing machine. 2. Choose the scale in the testing machine. 3. Measure the thickness and the diameter of the test specimen. 4. Measure the die throat diameter and determine R 5. Lubricate the die surface and its throat. 6. Place the specimen in position on top of the die and locate the die holder, and finally place the punch in a proper position. 7. Place the die set between the two platens of the testing machine.
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8. 9. 10. 11.

Applied the load gradually until the cup is completely drawn. Takes off the die set and get the formed cup. Measure the average height of the cup. Take off the outographics records of the test.

9. Requirements: 1. Experimentally, Draw the experimental punch load- punch travel displacement curve, use that curve to find the energy (area under curve) and the maximum drawing force (the peak value of the curve).

Calculate the theoretical height value of the cup and compare it with the experimental values, discuss the difference. 3. Calculate the theoretical value of the drawing energy required and compare that with the experimental value, discuss the difference and explain the difference relation with lubrication. 4. Calculate the theoretical drawing force value and compare that with the experimental value. 5. Discuss the following aspects of deep drawing; Pure drawing, Stretching drawing; wrinkling; ironing; earing; Tearing. 6. Discuss the effects of lubrication, blank holder force, Draw beads, and Clearances on the operation of deep drawing. 10. Questions: 1. Explain in details the following: a. Earing, b. Bell-shaped drawn products, c. Orange peeling;

2.

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