Successful deep drawing is a combination of many important factors. Deep drawing mechanism, parameters, defects and recent results. The general software available for metal forming processes are marc, cosmos, and abaqus. Types of press working or sheet metal operations pdf. Following is a list of common defects, with sketches in 2 figure. The main defects of deep drawn parts are wrinkling andor neckin.
The second objective is to identify the mechanical properties of. Defects that occur during deep drawing of sheet metal can be controlled by careful regulation of process factors. Metal fracture this is one of the most common deep draw problems. Blankingblanking is the process ofcutting the initial sheet coil stockinto round or shaped flatsrequired for deep drawing. Feb, 2021 defects in deep drawing material science and production engineering, gate mechanical engineering notes edurev is made by best teachers of mechanical engineering. Earing is one of the major defects observed in a deep drawing process due to the. Wrinkling in the flange of the drawn product, wrinkling in the wall of the drawn product, tearing in the drawn product, earing in the drawn product. Excessive thinning in areas of the sheet metal is also an unwanted defect. Therefore, it is important to optimize the process parameters to avoid defects in the parts and to minimize production cost. This is like ups and downs or waviness that is developed.
Prediction of wrinkling is a very important process for a deep drawing operation. Limiting draw ratio to express deformation limit in deep drawing. But, the edges of the blank will be lifted upwards and produce the foldings or wrinkles on the deep drawing component. Effect of various parameters on the wrinkling in deep drawing. Apr 01, 2021 a deep draw process may have one or more drawing operations, depending on the complexity of the part.
Finite element simulation of earing defect in deep drawing. Effects of various parameters in deep drawing process over. Mar 14, 2012 defect in deep drawing slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. This defect is more prominent with large grain size materials. Abstract a sheet metal forming smf process, especially deep.
Download limit exceeded you have exceeded your daily download allowance. Because a part wrinkled during the deep drawing process will not be accepted and most likely become as scrap. Achievements of nearly zero earing defects on spcc cylindrical. Apr 30, 2007 analyzing the effects of these factors on deep drawing formability, appropriate process parameters were selected to avoid forming defects in order to improve the ldr of workpieces. A copy can be downloaded for personal noncommercial research or study. Measurement of drawability by drawing ratio using swift cup test. On the other hand, necking is due to the excessive radial tensile stress. Effect of various parameters on the wrinkling in deep. Drawing ratio, punch corner radius, punch speed etc. Defects in drawing miss strike ydue to the misplacement of the stock, unsymmetrical flanges mayresult. Wrinkling usually occurs at the flange region by excessive compressive stresses leading to local buckling of the sheet.
The deep drawing process is a forming process which occurs under a combination of tensile and compressive conditions. The deep drawing experiments were carried out using the double action hydraulic press with the capacity. Earing is one of the major defects observed during deep drawing process due to anisotropic nature of sheet metal. 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.
The phenomenon of wrinkling flange instability is specific to the process of deep drawing. Formability analysis of crcais2 sheet to eliminates the defects. Deep drawing is a sheet metal forming process used industrially to produce cupshaped, boxshaped, and other. Effects of different parameters on deep drawing process. Numerical parameters for deep drawing simulation of a. The wrinkling defect occurs due to the application of uneven blank holding fo. Pdf this paper shows the finite element simulation of the deep drawing process where forming defects like wrinkling and material erosion of blank is. Deep drawing is a sheet metal forming process which is widely used in manufacturing parts for automobile and air craft industries. Optimization of deep drawing process for circular cup forming. In sheet metal forming, a blank sheet is subjected to plastic deformation using forming tools to conform to a designed shape. Optimization of process parameters in deep drawing process. Reduction of wrinkling defect in deep drawing process. Pdf prediction of forming defects in deep drawing process by. If you continue browsing the site, you agree to the use of cookies on this website.
Experimental work a set of deep drawing experimental facilities were designed to analyze formability of the edd steel alloy sheets. If this is too small, too large, or uneven, the material can be cracked during drawing. Pdf deep drawing is a sheet metal forming process which is widely used in. Din 8584 deep drawing processes are divided into three types. Formability analysis of deep drawing process by finite. Defects in deep drawing material science and production. This article illustrates the mechanics of the deep drawing of a cylindrical cup. The deep drawing may be broadly classified as a conventional deep drawing a nd a nonconvent ional deep drawing depe nding on the m ethod o f operation 7. Effect of forming conditions on localized thinning in deep. Metal forming operations in industries are performed by the sheet metal processes. The process is considered deep drawing when the depth of the drawn part exceeds its diameter. Pdf deep drawing mechanism, parameters, defects and recent.
Instability in the work piece, also called wrinkling of the walls. It is very important to make sure the reasonable process parameters and predict the forming defects. This paper aims to provide an overview of the deep drawing process and the deformations experienced by paperbased materials in the deep drawing process. The four major defects which can occur during deep drawing are fracture, wrinkling, earing and spring back.
As a manufacturer who offer onestop service for customized parts, we perform excellently in arena of sheet metal parts fabrication including bending, roll forming, deep drawing, spinning and so on. Otherwise, a good formability or product quality is related to proper part characteristics. Pdf prediction of forming defects in deep drawing process. May 12, 2018 deep drawability and its relation with plastic strain ratio.
Defects in deep drawing deep drawing is a more complex operation and more things can go wrong. The aim of this section is to overview the current process for deep drawing of paperboard, materials which are used for it, and common defects and problems in deep drawing. Due to improper clearance and punch force, defect was occurred in drawing components. In this research, analytical models were developed to investigate stress analysis and instability condition in hydromechanical deep drawing hmdd of cylindrical alst cups. A number of defects can occur in a drawn product of the deep drawing process. The workpiece material used in a deep drawing process is anisotropic in nature, due to a prior thermomechanical treatment. Jul 25, 2016 defects in deep drawing tearing maximum thinning of the cup wall occurs near the base, so, tearing of the sheet metal is most likely to occur in this region even if the stress is originating somewhere else wrinkling may often occur if the blankholder force is too low excessive thinning in areas of the sheet metal earing that is the formation. With the reliable technicians, advanced equipment, rigorous quality system, rebond is committed to avoiding 6 defects in sheet metal forming. Defects in deep drawing tearing maximum thinning of the cup wall occurs near the base, so, tearing of the sheet metal is most likely to occur in this region even if the stress is originating somewhere else wrinkling may often occur if the blankholder force is too low excessive thinning in areas of the sheet metal earing that is the formation. During this process, the blank sheet is likely to develop defects if the. Defects in deep drawing a number of defects can occur in a drawn product, some of which we have already alluded to.
Process the deep drawing type of the forming process for paperboard is already being applied at the industrial scale. Detection of cracks and thinning of material during deep drawing processes dr. Wall thickness is an important quality index of the drawing 6. Most common defects occurred during this process are wrinkle and tear. Circular cup drawing is the most basic process among the deep drawing processes. In the deep drawing process, deformation defects such as fracture and wrinkling have been found due to large deformation. Jun 01, 20 deep drawing stationtypes blanking drawing piercing trimming 8. Material drawn into shape conventional drawing stamping expensive tooling, no net thinning, quick hydroforming cheap tooling, no net thinning, slow, high.
In sheet metal work deep drawing plays a major role to form the desired. The punchdie clearance is slightly larger than the thickness of the sheet metal to be deep drawn. Earing is defined as formation of waviness on uppermost portion of deep drawn cup. Jul 02, 2019 table of content introduction to deep drawing process common defects and their remedies flange wrinkle and wall wrinkles step rings draw marks orange peel scratches fractured flange and bottom corner fracture miss strike directional earing shankar kumar pgwlf1850156 2 3. The main defects of deep drawn parts are wrinkling andor necking. Chapter two aspects of deep drawing and microscale. The macroscopic appearance of 304 stainless steel deep drawing product is a. Prediction of earing defect and deep drawing behavior of commercially pure titanium sheets using cpb06 anisotropy yield theory. The article summarizes the defects in drawing and factors considered in press selection for drawing. In deep drawing process the main objectives are to obtain defect less or.
In this experiment both steel and copper were taken as a base material and deep drawing process was finished with different parameters and defect. Based on these models, several parametric study were performed regarding to the effect of thickness of layers, setting condition of layers, drawing ratio and frictional. They cause defects in deep drawing such as surface and complete fractures, appearance defects, and shape inaccuracies. Deep drawing of a double bowl sink is modeled and simula tions are done.
This document is highly rated by mechanical engineering students and has been viewed 33 times. One of the primary defects that occurs in deep drawing operations is the wrinkling of sheet metal material, generally in the wall or flange of the part. Theoretical study on hydromechanical deep drawing process. Sheet metal is drawn in either hydraulic or mechanical presses. Material deformation and wrinkling failure in deep drawing. Theoretical study on hydromechanical deep drawing process of. Study of earing defect during deep drawing process with. Concordia universitymech 4216511 lecture 97 analysis of drawing measure of drawing. Prediction of earing defect and deep drawing behavior of. Tearing is caused by excessive tensile stresses leading to fracture of the sheet while excessive compressive stresses during forming cause wrinkling. 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. Pdf effect of mechanical properties on deep drawing.
The deep drawing process is a techniquetool which is often applied to fabricate hollow sheet metal parts with complicated shapes. In this experiment both steel and copper were taken as a base material and deep drawing process was finished with different parameters and defect was analysed. 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. In deep drawing process the main objectives are to obtain defect less or minimum defects in product. Deep drawing is one of the most widely used processes in sheet metal forming, in which a sheet metal blank is. Paper open access related content deep drawing mechanism. The deep drawing is a metal forming process used for manufacturing. Volume 212, issue 9, september 2012, pages 18401849. It discusses the fundamentals of drawing and drawability. This article highlights only the most frequently violated design and build principles. Control of sheet surface defects and deep drawing properties in final strip production steps. Wrinkling and tearing are two major issues that induce irregularities in the formed part. Deep drawing is a sheet metal forming process which is widely used in. Failure of sheet metal parts during deep drawing processes usually takes place in the form of wrinkling or tearing.
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