Deep drawing

A drawing operation begins with a flat metal blank which is transformed into a cup, shell, boxes,
and similar articles.

When the depth of the product is less than its diameter (or the smallest dimension of its opening),
the process is considered to be a shallow drawing. If the depth is greater than the diameter, it is
known as deep-drawing.

1
All drawn products can be placed in two groups: (i) Drawn shells with flanges (ii) Drawn shells
without flanges

Drawing of flanged cup

2
Drawing of flanged cup

Drawing

Shallow drawing Deep drawing

Shallow drawing Deep drawing

1. h
≤ 0.75 (LDR 2) h
d > 0.75
d
2. Shallow drawing is completed in Deep drawing requires more than one
one draw draws to obtain a cup of requisite h and d
3. A blank holder is not required. A blank holder is required for deep
drawing
Direct and Indirect redrawing

3
4
5
Blank Development: It is a determination of the blank diameter for forming the cup. The basic
principle underlying all these methods is the surface area of the drawn shell is equal to the surface
area of the blank. Determine the blank development in the case of a circular flangeless cup as
follows.
d
Blank diameter depends on ( r ) ratio

d
( r ) ratio

d
≥ 20 d0 = √d2 + 4dh
r

d
15 ≤ r < 20 d0 = √d2 + 4dh − 0.5r

d
10 ≤ < 15 d0 = √d2 + 4dh − r
r

d
< 10 d0 = √(d − 2r)2 + 4d (h − r) + 2πr(d − 0.7r)
r

r = corner radius
h = height of the cup
d = Ø outside cup diameter

6
d0 = Ø blank diameter.
Some recommend a formula for calculating all types of drawn shell blanks as
d0 = √d2 + 4dh − 3.44 r d
Flanged cup

a = arm length; r1 = corner radius; r2 = cup (fillet) radius

d0 = √(d + 2 a)2 + 4 d [h − 0.43 (r1 + r2 )]

A cylindrical cup shown in fig having a diameter of Ø100 mm and height of 125 mm
is to be made from a flat sheet 1 mm thick. The radii between the flange and the
cylindrical section and the cup bottom are 4mm each. The yield strength of the sheet
is 200 MPa and UTS 450 MPa. Determine (a) blank diameter (b) processing
sequence (c) the load required to draw the first stage.

7
d0 = √(d + 2 a)2 + 4 d [h − 0.43 (r1 + r2 )]

= √(134)2 + 4 × 100 × [125 − 0.43 (4 + 4)] = Ø258 mm

Two stages of drawing

d1 = Ø143 mm

d2 = Ø100 mm

F = 236154 N = 24 T

The first draw with 45% and the second draw had 35%

d0 260
F1 = π × d1 × t × Su [ − 0.65] = π × 143 × 1 × 450 × [ − 65] =236154 N = 24 T
d1 143

d1 = outer diameter of the drawn cup

Su = UTS
C = constant to cover friction and bending (0.6 to 0.7 for ductile materials)
Find the blank diameter for the cup shown:
The component can be divided into two parts the hemispherical bottom with a 25 mm inside
radius and the cylinder with Ø 50 mm ID.
(i) Mean radius for hemisphere = 26 mm
2
The surface area of the hemisphere = 2 π rm = 2 π × 262 = 4247mm2
(ii) Mean diameter of the cylinder = 2 rm = 52 mm
The surface area of the cylinder = π dm h = π × 52 × 30 = 4900 mm2
(iii) Total surface area = 4247 + 4900 =9147 mm2
Let d0 = Ø blank diameter
π
× d20 = 9147
4
d0 = Ø108 mm
Layout: As per Pappu’s theorem, the area swept by a line of any contour as it revolves about an
axis is equal to the length of the line multiplied by the center of gravity of that (line) contour.

8
 L1 x1 + L2 x2 + L3 x3 + L4 x4
x̅ =
L1 + L2 + L3 + L4
Surface area generated in one revolution
A = 2π (L1 + L2 + L3 + L4 ) x̅
π
The surface area of the blank = 4 d20
π 2
d = 2π (L1 + L2 + L3 + L4 ) x̅
4 0
d0 = √8 x̅ (L1 + L2 + L3 + L4 )

9
10
Trimming Allowance:

The above formulae provide the theoretical blank size. Extra metal should be added to the formula
blank diameter to provide for trimming, which is necessary on deep-drawn cups to eliminate the
uneven and irregular edge on the rim of the drawn cup. The extra material added to the blank
diameter is referred to as trim allowance.

When sheet metal is rolled, a fiber structure is formed in the direction of rolling. The sheet metal
is stronger and has greater allowed elongation in the direction of rolling. Strength is lower across
the direction of rolling. Due to this variation in strength, the top edge of the shell is wavy. This
wavy phenomenon is called earing. This objectionable wavy edge increases the height of a drawn
cap and must be allowed for (as allowance for trimming) when determining the blank diameter.

For practical purposes, it is necessary to add allowances for trimming the uneven and irregular rim
of the deep-drawn cup. This allowance is termed a trimming allowance.
1. Trimming allowance is about 3 to 5% of the blank diameter.

11
2. The trimming allowance could be 3 mm for the first 1” (25.4 mm) cup diameter and an additional
3 mm for each additional 1” cup diameter.
d−25
 Trimming allowance = 3 + 3 × ( ) where d = Ø cup diameter
25
2. Determine the number of draws required.
h
The number of draws required is determined using percent reduction and the ratio (d) of the cup.
Reduction and number of draws:
Grain sizes of ASTM 5 or coarser may result in excessive surface roughness as well as reduced
drawability. The preferred ASTM size is 7 or more.

The operation is usually divided into two main groups: first-stage drawing, in which a flat circular
metal blank is made into a cup; and a redrawing stage/s in which the cup attains its final size. The
latter operation is necessary because first-stage drawing cannot normally produce a higher degree
of deformation than that defined by the ratio of the diameter of the blank and the die throat
(drawing ratio) of about 2.2, or a cup height/diameter ratio of about 1.

When a flat blank of diameter d0 is drawn into a cup of a diameter d1 , the initial circumference is
π d0 reduced to a much smaller circumference π d1 . Consider a small sector of the cup. The
length AB, L is reduced to the length A′ B′ L′.
π d0 − πd1 d
Percent reduction = ( ) × 100 = (1 − d1 ) × 100
πd0 0
h
The number of successive draws required is a function of the ratio of (d), and is given by this
formula:
h
n = f (d)

n = number of draws

12
h =part height
d = part diameter Ø
The draw ratio is defined as the ratio of the draw height to shell diameter. It is an important
consideration in estimating the number of draws.

The blank diameter divided by the punch diameter gives the limiting draw ratio (LDR). In this
h
case, the sidewall height is 37.5 mm, and the resulting d
= 0.75. The LDR is 2.25 for commonly
formed metals, brass, and austenitic stainless steels (55.5%) reduction and 2.5 for interstitial-free
steels (60%).

Numbers of draws (n) for a cylindrical cup draw

h < 0.6 0.6 −1.4 1.4 −2.5 2.5− 4.0 4.0 − 7.0 7.0 −12.0
( )
d

n 1 2 3 4 5 6

The reduction in the first draw is generally limited to 45% for mild steel and aluminium whereas
brass, and bronze can be reduced by 50%.
The maximum reduction possible in the first draw is given by
Material Maximum reduction (%)
Brass, bronze, stainless steel 50
Aluminium alloys, copper, low carbon steel 45
zinc 40

13
 h
The ratio (d) can guide the number of draws required
h No. of Percent reduction
(d) ratio
draws
first draw second draw third draw fourth draw
Up to 0.75 1 45 − − −
0.75 − 1.5 2 45 30 − −
1.5 − 3.0 3 45 30 20 −

3.0 − 4.5 4 45 30 20 10

d1 d d
Let a cup needs 4 draws to obtain the cup which provides for = 0.55, d2 = 0.7, d3 = 0.8, and
d0 1 2
d4
= 0.9, where d4 is the final cup diameter and d0 is the blank diameter. Thus, it enables the
d3

determination of diameters after the first and subsequent draws.

14
 Drawing ratio for the ith draw. The draw ratio is defined as the ratio of the draw height to shell
diameter. It is an important consideration in estimating the number of draws.

di
βi = d
i+1

The draw ratio is controlled by several basic factors:

• The mechanical properties of the metal, primary its “r” value or thickness strain ratio, which is its
ability to flow plastically and resist thinning.
• Material thickness
• Die geometry
The total drawing ratio is equal to the product of the drawing ratios of all the draws.
βT = ∏ni=1 βi = β1 × β2 × β3 … .× βn
A large total drawing ratio (βT ) is obtained by choosing the drawing ratio for the first draw as
large as possible. For deep drawing steel without annealing βT = 6.5 is obtainable without failures.
Under these circumstances, wall thickness ratios of about 1. 2 result from the thinning at the punch
radius and thickening at the upper edge of the cups.

15
5. Clearance

The clearance per side of 7 to 15% greater than the stock thickness (1.07 to 1.15t) helps prevent
burnishing of the sidewall and punching out of the cup bottom. The drawing force is minimal when
the clearance per side is 15 to 20% greater than the stock thickness (1.15 to 1.20 t). The force
increases as the clearance decreases, and a secondary peak occurs on the force-stroke curve where
the metal thickness is slightly greater than the clearance and where ironing starts.

Redrawing operations require greater clearance than the first draw to compensate for the increase
in metal thickness during cupping. A sizing redraws is used where the diameter or wall thickness
is important or where it is necessary to improve surface finish to reduce finishing costs. The
clearance used in the sizing draw is less than that for the first draw.

Clearance in cutting operations is relatively small, usually 3% to 8% of sheet metal thickness. In

deep drawing manufacture, if the clearance is too small the sheet may be cut or pierced, (not well),
despite the radius. Clearance in deep drawing manufacture is greater than sheet thickness, usually,
clearance values are 107% to 115% of sheet thickness.

16
The space between the die and the punch is kept intentionally larger by 7 to 15% of the metal sheet
thickness. This additional gap over and above sheet thickness is called die clearance. In addition
to providing space for wall thickening, the clearance reduces friction between the die wall and the
workpiece. Note that die clearance increases as the thickness of the metal sheet increases. The
redrawing dies have about 12% more die clearance than the first draw dies. On the other hand,
finishing (sizing) dies have about 60% less die clearance than the first draw dies.
Clearance for the first drawing for cylindrical shells
Material Per-side clearance
Aluminium 1.25 t
steel (1.1 to 1.25) t
Stainless steel (1.75 to 2.25) t

Clearance gap (c) per side can be determined as follows:

Draw Number First Second Third Final (sizing)

Clearance gap (c) per side 1.05 t 1.09 t 1.1 t 1.03 t

Another The clearance between the walls of the punch and the die
c = t + k √10 t

Material Coefficient k

17
 Aluminum sheet 0.02

Other metal sheets 0.04

Steel sheet 0.07

6. Die Radius

Drawing is promoted by increasing punch and die radii. For a given drawing condition, the punch
force needed to move the metal into the die decreases as the die radius increases.

Since the draw die radius does not contribute to the cup shape, it can be made as large as possible.
A larger die radius facilitates metal flow. However, if the draw radius is too large, the metal will
be released by the blank-holder too soon and wrinkling will result. A general rule is to make the
die radius four times the metal thickness. Too large die radius results in sheet unsupported over
longer length & early release by the blank holder. This leads to edge wrinkling. A small die radius
on the other hand hinders the metal flow and causes thinning and tearing of the sidewalls of the
cup as metal flow over the cup die corner becomes problematic & difficult. The draw radius is
about 4 times the stock thickness for drawing without a blank holder and 6 t – 10 t with a blank
holder.

The basic recommended sizes of tooling radii for drawing punches and dies are:
A mathematical method of evaluation of the proper size of the first drawing dies radius follows.

rd = √0.8 (d0 − d1 ) t

the radius size of (6 to 10) t for a single-pass drawing operation.

18
For all redrawing dies, the above formula becomes

d1 − d2
rd = ( )−t
2

1. If the draw radius is too large, the metal will be released by the blank holder earlier and
wrinkling will result.
2. Too small/sharp a die radius will hinder the normal flow of the metal and cause uneven
thinning of the cup wall, with the resultant tearing. The general rule is to make the die
radius 4 times the material thickness. The draw radius may be increased to 6 to 8 times the
metal thickness when drawing shallow cups of heavy gauge materials without a blank
holder.
3. The center point of the draw radius should be approx.3.2 mm outside the cup
To minimize the thinning of stock –

(i) The center point of the draw radius should be approximately 3.2 mm (1/8”) outside the
previously drawn cup.
(ii) The center point of the punch radius should be slightly inside the following drawn cup.

Punch Radius

A sharper radius on the punch results in a higher force requirement as the metal is folded around
the punch nose and may result in excessive thinning or tearing at the bottom of the cup. A general
rule to prevent excessive thinning is to design the punch with a radius from 4 to 10 times the metal
thickness. If the radius must be less than 4 times the stock thickness, it may form over a larger
punch radius and then strike it to develop a specific radius. When many draws are required, the
punch radius for each redraw should be proportionately smaller than that of the preceding shell.

19
Drawing punches must have a corner radius exceeding 3t. However, the punch radius should not
exceed one-fourth of the cup diameter (d). Thus, the limits can be stated as

d
3 t < rp <
4

The punch radius is determined by the product when only one draw is necessary to complete the
cup because the cup bottom takes the shape of the punch nose.

Drawing punch values differ with the diameter of shell d as follows:

For d = Ø 6.3 to 100 mm, rp = (3 to 4) t

For d= Ø 100 to 200 mm], rp = (4 to 5) t

For d = 200 mm, rp = (5 to 7) t

To minimize thinning of the stock, the center of the corner radius on the punch should be slightly
inside the shell of the next draw. When more than one draw is required, the punch radius for the
preceding draw should be at least 3 mm inside the die edge for the following operation. Thus we
have to work backward from the finished radius of the cup to the preceding draw to keep the
centerline of the radius about 3mm inside the following draw.

Press selection on deep drawing

Drawing force, die space, and length of stroke are the most important considerations in selecting
a press for deep drawing. When blank-holder cylinders are mounted on the main slide of the press,
the blank-holder force must be added to the calculated drawing force. For round work, the
allowance for blank-holding should be 30 to 40% of the drawing force. For large rectangular work,
the drawing force is relatively lower than that for round work, but the blank-holding force may be
equal to the drawing force. Where stretching is involved and the blank must be gripped tightly
around the edge (and a draw bead is not permissible), the blank-holding force may be two or three
times the drawing force.

Drawing force
d0
F1 = π × d1 × t × Su [ − C]
d1

d1 = outer diameter of the drawn cup

Su = UTS
C = constant to cover friction and bending (0.6 to 0.7 for ductile materials)
20
The UTS of different materials
Material C20 C20 C40 C40 Stainless Brass Copper Al
HR CR HR CR steel 301

σu 38 42 52 60 70 32 22 9
kgf/mm2

Total work = 70% for radial drawing + 13% to overcome the friction + 17% bending and
unbending.

Drawing Punch force = Fdeformation + Ffrictional + (Fironing)

Blank holding force

Smaller die radius, greater stock thickness, and blank holding pressure offers resistance to metal
flow in drawing operation. The blank holding force is about 30 to 40 % of the drawing force. There
are no absolute rules for determining it but it is found empirically. Blank holding force should be
just enough to prevent wrinkling. The excessive blank holding force would cause cup failure
through the separation of the cup-bottom from the rest.
μ Fb > π d t S u
Since the blank-holder pressure causes higher frictional forces, it should only be high enough to
prevent the wrinkling of the metal. The blank-holder pressure that is too high will cause the metal
restriction and tearing of the cup wall.

The blank-holder pressure cannot be reduced below a point where the wrinkling of the metal
occurs. A lubricant is applied to reduce friction. Shallow draws in light stamping can be produced
with little or no lubrication, but when forces become larger and scoring, wrinkling, and tearing
becomes a problem, a lubricant must be used.

The amount of blank holder force required is usually approximately one-third of that required for
drawing. There are no absolute rules for calculating blank holder force for a given drawing
operation; most blank holder force values are found empirically. Blank holder force should be just
sufficient to prevent wrinkling, and it depends on draw reduction, work metal thickness and
properties, the type of lubrication used, and other factors.

p = blank holder pressure

21
 π
Blank-holder force = p × area of sheet metal holding = p × 4 (d20 − d12 )

Material p (N/mm2 )
Deep-drawing steel 1−3
Low-carbon steel 3−5
Aluminum and aluminum alloys 0.85 − 1.4
Aluminum alloys, special 3.5
Stainless steel, general 2 −5
Stainless steel, austenitic 7
Copper 1.25 − 1.75
Brass 1.40 − 2.0

The severity of wrinkling is judged by (t/d) ratio criterion.

(t/d) × 100 Wrinkling

Wrinkling is severe and compressive load must be reduced. A blank

Less than 0.5
holder must be used so a double-action press is required.

0.5 to 1.5 Wrinkling is moderate and lower blank holding force is required.

Wrinkling is slight and a single-action press can be used.

1.5 to 2.5

No wrinkling is expected.
Greater than 2.5

The purpose of a press lubricant is to provide a film between the blank and the punch and die. The
film must be strong enough to permit deformation without being squeezed between the surfaces.
[i] when pressures are low, straight mineral oils or general-purpose soluble oils, or a diluted soap
solution are found satisfactory, as these pressures will not rupture the film.[ii] At greater pressures,
lubricants containing sufficient oiliness ( polar minerals such as fatty oils, waxes, and concentrated
soaps) are used. The oiliness will not allow the squeezing of lubricants.

Stroke length

22
Parts that have straight walls can often be drawn through the die cavity and then stripped from the
punch and ejected from the bottom of the press. Even under these ideal conditions, the minimum
stroke will be equal to the sum of the length of the drawn part, the radius of the draw die, the stock
thickness, and the depth of the die to the stripping point, in addition to some clearance for placing
the blank in the die.

Parts with flange are required to be removed from the top of the die. Press strokes must be at least
2.5 times the stamping depth to the removal of the part from the open die. For example, a cup 50
mm deep needs 50 mm to clear the die cavity and another 50 mm to clear the punch a little more
space is required between part and die surfaces. Stoke of over four times the stamping depth is
often used.
Workpieces with flanges or tapered walls must be removed from the top of the die. In drawing
these workpieces, the minimum press stroke is twice the length of the drawn workpiece, plus
clearance for loading the die. In an automatic operation using progressive dies or transfer
mechanisms, at least one-half of the stroke must be reserved for stock feed because the tooling
must clear the part before feeding begins for the next stroke. For automatic operation, it is common
practice to allow a press stroke of four times the length of the drawn workpiece

The drawing formation starts at the die surface and ends at the bottom dead center. The bottom
drawn part of a completely formed product comes above the die surface making it easier to take it
out. In addition, unless there is some additional margin, the working becomes difficult. Therefore,
in manual operations, a stroke length of more than 2.5 times the product height becomes necessary.
When carrying out automatic forming, since time is required for material movement, a stroke
length of more than three times the product height can be said to be a safe stroke length. However,
caution should be exercised because too long a stroke length decreases the working efficiency.
With a short stroke, there are the problems that it is difficult to see inside the die and that it is
difficult to take out the product, which also reduces the work efficiency and is dangerous at the
same time.

23
Parts with flange are required to be removed from the top of the die. Press strokes must be at least
2.5 times the stamping depth to be the removal of the part from the open die. For example, a cup
50mm deep needs 50 mm to clear the die cavity and another 50mm to clear the punch a little more
space is required between parts and die surfaces. Stokes of over four times the stamping depth are
often used.

Stroke length = 4 x depth of the drawn part

Part without flange

Stroke length = 2 x depth of the drawn part

Drawing speed

The speed with which the punch moves through the blank during drawing is termed drawing speed.
It is a very important parameter in drawing because higher speeds cause cracking or excessive
thinning, particularly in harder and less ductile materials. Therefore, a slower drawing speed
should be used for drawing harder and less ductile materials, low carbon steel is drawn at a lower
speed (1 to 15 m/min) than nonferrous (50 to 60 m/min). Lower speeds reduce the production rate,
which is also undesirable.

24
When cracking or excessive thinning occurs, the drawing speed must be reduced, close control of
drawing speeds is not possible, especially on mechanical presses and therefore hydraulic presses
are preferred to mechanical where close control of drawing speed is possible.

Material Drawing speed (m/s)

Steel 0.25 (15 m/min)
Copper / zinc 0.75 (45 m/min)
Aluminum 0.90 (54 m/min)
Brass 1.00 (60 m/min)

Air vent

It is provided in the punch to reduce the possibility of the formation of a vacuum in the cup when
it is stripped from the punch. For a cylindrical shell, one vent located centrally would be enough
whereas for other shapes it may be advantageous to provide two. The size of the air vent depends
on the punch diameter.

Punch diameter Air vent diameter (Ø)

Up to 50 mm 4.5 mm

50 -100 mm 6.0 mm

100 -200 mm 7.5 mm

Over 200 mm 10 mm

25
Dies for drawing

Dies used for drawing sheet metal are usually one of the following basic types or some
modification of these types:

❖ Single-action dies
❖ Double-action dies
❖ Compound dies
❖ Progressive dies
❖ Multiple dies with a transfer mechanism
Single-action dies are the simplest of all drawing dies and have only a punch and a die. A nest or
locator is provided to position the blank. The drawn part is pushed through the die and is stripped
from the punch by the counterbore in the bottom of the die. The rim of the cup expands slightly to
make this possible. Single action dies can be used only when the forming limit permits cupping
without the use of a blank-holder.

Compound Dies

When the initial cost is warranted by production demands, it is practical to combine several
operations in a single die. Blanking and drawing are two operations commonly placed in
compound dies. With compound dies, workpieces can be produced several times as fast as simple
dies.

Progressive Dies.

The initial cost and length of bed needed for progressive dies usually limit their application to
relatively small workpieces. The total number of parts to be produced and the production rate
often determines whether or not a progressive die will be used when two or more operations are
required. Practical considerations that may rule against a progressive die, regardless of quantity:

❖ The workpiece must remain attached to the scrap skeleton until the final station, without
hindering the drawing operations.
❖ Drawing operations must be completed before the final station is reached.
❖ In deep drawing, it is sometimes difficult to move the workpiece to the next station.
❖ If the draw is relatively deep, stripping is often a problem.
❖ The length of the press stroke must be more than twice the depth of draw, practically 4
times.
Transfer dies

26
Multiple dies, in conjunction with transfer mechanisms, are often used instead of progressive dies
for the mass production of larger parts. Multiple dies and transfer mechanisms are practical for a
wider range of workpiece sizes than progressive dies are. The production rate for the transfer
method is usually greater than that for a single-die operation but 10 to 25% less than that for
drawing in a progressive die.

Cross-section of beveled drawing surface of a simple, push-through drawing die

Cross-section of beveled drawing surface of a simple, push-through drawing die

27
Cross-section of beveled drawing surface of a simple, push-through redrawing

Cross-section of beveled drawing surface of a simple, push-through redrawing die with inner
blank-holder.

28
Rectangular Cup Drawing

Blank development

Centers of the corner radii R c of the blank lie on the centerlines of radius ‘r’ on the bottom of the
box. Corner radius Rc can be found from the following equation:

R c = √R2 + 2 R h − 1.141 R r

where R= Corner radius joining the vertical side of the box

r = Corner radius joining horizontal bottom to vertical sides of the box

h = Height of the box

To find the shape of the corners, draw an arc with a radius R c from centers A, B, C, and D. (Refer
𝜋𝑅
to fig 3). Then draw lines representing the top edge of the box at a distance (ℎ + ) from the
2
lines passing through A, B, C, and D. Draw the blending radius in such a way that it is tangential
to the lines representing the top edges of the corner radius as drawn earlier. The corner radius and
the blending radius together constitute the corner profile of the blank.

29
Corner Radius and Box Height:

Fig 3 also shows the recommended radii between the sides and bottom. The corner radius
between the sides should preferably be more than one-tenth the length L of the box. The radius
joining the bottom to the sides ‘r’ generally ranges from 3 to 8 times the blank thickness (r = 3 to
8t). The height of the box ‘h’ depends upon the corner radius R between the sides

𝐻 + 𝑟 ≤ 12𝑅 If R ≤ 6

𝐻 + 𝑟 ≤ 6𝑅 If 12 ≤ R ≤ 25

The force required to draw a rectangular cup can be calculated using

h C1
F = su t [2π R C1 + L C2 ] (R)

R = the corner radius of the cup 2 0.5

L = the sum of the lengths of straight sections of the sides 6 2.0

h
C1 = Constant depending on the ratio (R)

C2 = 0.2 (for easy draw radius, ample clearance, and no blank-holder force) to a maximum of 1.0
(for metal clamped too tightly to flow).

30
Find the force required for drawing a box made from a 2 mm thick M.S sheet having 250
mm length and 150 mm width. The radius between the sides ‘R’ is 25 mm whereas the
radius joining sides to bottom ‘r’ is 8 mm. The box is 50 mm deep. The tensile strength of
the blank is 420 N/mm2

F = su t [2π R C1 + L C2 ]

su = 420 N/mm2 t = 2 mm L = 250 mm W = 150 mm

R = 25 mm r = 8 mm

h = 50 mm

h
(R ) = 2 ∴ C1 = 0.5 C2 = 0.25

F = su t [2π R C1 + L C2 ]

= 420 × 2 × [2π × 25 × 0.5 + 250 × 0.25]

= 118473N  12 tonnes

Stages in the drawing

Elongation constraints of worksheet material limit the maximum reduction possible in a single
draw. As each draw work hardens the worksheet material to some extent, the resultant loss of
ductility reduces the reduction in the subsequent draw.

When many draws are used to obtain the final shape, it is formed gradually. The corner radii and
bottom radii of earlier stages are much more liberal than the final sizes. The blank is first drawn
to a circular cup with a chamfered corner. In the second stage, the cup has got sides with large
radii. The third and the final draw finish the workpiece to the required size. Note the big chamfer
at corners joining vertical sides with base in the first stage. Even in the pre-finishing draw,
vertical sides are connected with a large radius. The following table states the number of draws
for various ratios:
h Up to 6 7 – 12 13 – 18 19 – 24
( )
R
No. Of Draws 1 2 3 4

31
 Drawing Rectangular Cups (Fig 3)

R c = √R2 + 2 R h − 1.141 R r

r = (3 − 8) t

𝐻 + 𝑟 ≤ 12𝑅 If R ≤ 6

𝐻 + 𝑟 ≤ 6𝑅 If 12 ≤ R ≤ 25

Determine the blank size to obtain a rectangular box made from a 2 mm thick copper sheet
with an overall dimension of 184 mm in length and 104 mm in width. The radius between
the sides to the bottom of the cup is r = 6 mm and between the sides is 20mm. The box is
33mm deep. Determine the tonnage required to obtain the cup if the tensile strength of the
material is 220 N/mm 2.

L = length of the cup = 184 mm (outside)

W = width of cup = 104 mm
r= corner radius joining the sides of the cup = 20 mm
rb= radius joining walls to the horizontal bottom
h= straight height of the cup = 25 mm
H= overall height of the cup = 25+6+2=33mm
t= cup wall thickness = 2mm
Steps

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 1. The layout of rectangular by drawing lines through the loci of workpiece corner radii.
These lines are primary datum.
2. Size of rectangle L1= L-2t-2r = 184-2x2 -2x 20 = 140
3. Width of rectangle w1= w- 2t -2r = 140-2x2
= 124-2x2x2x20= 80

Primary datum is a ABCD.

2. The width of metal needed for side wall and bottom radius (rb) is h+ (𝜋/2)x rb where
h is straight side wall and rb is bottom inside radius. This width is added to each side
of rectangular layout obtained in step 1 (i.e. primary datum)
3. The corner radius Rc of the blank which provide metal needed for each corner of the
shell is
4. Rc = r2 + 2rh – 1.141r.rb
As
h= 25 mm
rb= 6mm
r=20mm
Rc= r2 + 2rh – 1.141r.rb
= (20)2 + 2 x20 x 25 – 1.141 x20 x 6
= 35.5 mm
Also,
= h+ (𝜋/2) x rb = 25 + 𝜋/2 x 6 = 34.5mm
From drawing overall blank size:
L = (184- 2x8) +2x34.5 = 237mm
W = (124-2x8) + 2x34.5 = 177 mm

The force required for rectangular drawing can be found using the following equation

F= σu t (2 𝜋 .r.c1 + 0.25L)
Where
σu =UTS of the material = 260N/mm2 (given)

t= blank/cup thickness= 2mm

r= corner radius between vertical sides = 20 mm
t= length of the box= 184 mm
h/r= 25/20= 1.25

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F= 260 x 2 x (2 𝜋 x20 x 0.5 + 0.25x 184) = 56592 N
= 56.6 KN
= 5.7 Tonnes

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