ISSN: 2277-3754

ISO 9001:2008 Certified

International Journal of Engineering and Innovative Technology (IJEIT)
Volume 9, Issue 11, May 2020

Design Analysis and Development of Draw Die

for Cylindrical Cup formation
Thejas.S1, Vaishnav.N1, Ajmal Roshan P.P1, Akshay. K1 Jibi.R2
1
Graduate Students 2Assistant Professor
Department of Mechanical Engineering AWH Engineering College Calicut Kerala India
Cause and effect diagram one of seven quality tool is used
Abstract— Various components used in mechanical industry to analyze various parameter which effect wrinkling defect.
especially automobile and aircraft industry are manufactured by
sheet metal. Press tools are used to produce particular sheet metal
II. METHODOLOGY
components in large amount. Accuracy of components depends
up on press tool construction and configuration. Main Methodology is the most important element to be
characteristic of press working operations are high rate of considered to make sure the fluent of the project and get
production associated with low unit cost production. Aim of the expected result.
project is to conceptual design through geometrical modeling in In other words methodology can be described as a frame
2D sketch and three dimensional modeling make easy work. Where it contains elements of work based on objectives
understanding of press tool construction. Cad model prepared
and scope of the project. A good frame work can get overall
using Auto CAD and Auto Desk Inventor. Structural analysis
carried out to analyze deformation and stress distribution. Quality view of the project and get the data easily. This includes
control tool cause and effect diagram which is used to analyze literature survey 2D and 3D modeling of Blanking and
various parameter which effect wrinkling. drawing tool and analysis and development of blanking and
drawing tool.
Index Terms—Press Tool, Cad, Auto Desk Inventor,
Wrinkling, Geometrical modeling, and conceptual design.

I. INTRODUCTION
Mass production always pointing towards increasing
quality and productivity. Press working also called stamping
or sheet stamping is a cold working process happening in
below recrystallization temperature. Press working operations
are important operation of converting raw material in to a
finished product. Press tool are mechanical devices used for
producing sheet metal component in large volume Press
working processes are carried out on working material in the
form of sheet. Metal having thickness less than 6mm is called
strip. Metal having thickness greater than 6mm is called plate
This work focus on designing two separate open tools used
for cylindrical cup formation. Step by step designing
procedure for blanking and drawing tool are deeply followed.
Various solid modeling packages are available in order is
to easy model the press tool. Auto Desk inventor is a basic
level software package available. 2D and 3D design of tools
make easy understand for various functions of each
components of a fixture. Two dimensional and three
dimensional modeling of the components, analyzing stress
and displacement on the components. Modeling and structural
analysis of the components was carried out on Auto Desk
inventor. Fig: 1 Methodology
Predominant failure modes in sheet metal parts in drawing
process are wrinkling. The prediction and prevention of III. LITERATURE REVIEW
wrinkling is extremely important in the design of tooling and
 Various Press working operations
process parameter in drawing process.
Sheet metal operations done on a press may be grouped in
Manuscript received: 24 April 2020 to two category cutting operations and forming operations .in
Manuscript received in revised form: 22 May 2020
cutting operation work piece is stressed beyond its ultimate
Manuscript accepted: 07 June 2020
Manuscript Available online: 15 June 2020

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 ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 9, Issue 11, May 2020
strength. In forming operation stress below ultimate strength. 2. Combination Die
Various cutting operations are It is combination die in which more than two operations
Piercing: operation to make hole or cut out opening of may be completed at one station i.e. cutting operations and
regular or irregular shapes in the blank /stamping. The forming.
punched out piece is slug. 3. Progressive Die
Blanking: Process of producing flat stamping. The entire Progressive die has series of station at each station one
periphery is cut out and the cut out piece is called blank. operation on work piece within one stroke of press machine &
Blanking is cutting a whole piece from sheet metal along a each time metal strip is transfer to next station.
closed contour. 4. Transfer Die
Notching: The process of removing a small area of metal Unlike progressive die the metal strip is feed progressively
from one or both edge of the strip. from one station to another. In transfer die the already cut
Parting; An operation that separate the stock material blanks are feed mechanically from one station to next station.
along a straight line in a double cut line.  Press tool terminology
Cutt-off: An operation to separate the component from the The figure below shows press tool terminology
stock material along a straight line in single cut line.
Lancing: Combination of cutting and forming operation. In
this operation no material is cut off from the stock material.
Trimming: Secondary operation to remove distorted and
excess metal from draw components.
Shaving: Small amount of material is removed from edge
of a blank or pierced hole. Considered as secondary
operation.
Perforating: Process of piercing a series of hole of
different shapes in a blank.
Various non cutting operations are
Bending: In this operation shape the material around a
straight axis which extends completely across the material.
Forming: In this operation shape the material around a Fig: 2 Press Tool Terminologies
curved axis instead of straight axis. Shank: It is an element of press tool which act as a
Drawing: In this operation flat blank is transferred in to connecting link between the press tool and press. The
cylindrical cup. diameter of the shank should fit in to the bore in the press tool
Curling: Rolling the edge of the component in to roll or a ram.
curl. The purpose being to strengthen the edge and to produce Top plate: This is the plate on which the top half /moving
a protective edge. half of the press tool is fixed. Shank is also fixed on top plate
 Press tool which connects the tool to the press.
Press tools are tools manufactured to produce a particular Thrust plate/black plate: This is case hardened steel plate
component either punched or formed with high degree of mounted below the top plate to avoid digging in off the
precision out of sheet metal. In this type of tooling no chip hardened punch in to top plate.
formation. Punch holder: It is mild steel plate which holds the punch.
Types of Dies The punch is fitted to the punch holder with a light press fit.
According to operation: Cutting or shearing die and Punch and Die: These are cutting element of the tool.
forming or non cutting die. They are usually made of high carbon high chromium steel,
According to method of operation and are hardened and tempered.
a) A simple dies to perform only one operation. Stripper: The main function of the stripper is guide the
b) Multi operation die -these dies are designed to perform punch in to die and also strip the stock material of the punch.
more than one operation in one stroke of ram. These are
Piolet: The function of piolet is to position the stock
further classified as below.
material accurately and bring the material in to proper
I. Compound Die
II. Combination Die position for succeeding operations.
III. Progressive Die Stopper: These are used for correct spacing of sheet metal
IV. Transfer Die for corresponding press operation over the die plate.
1. Compound Dies Guide pillar and bush: These are used to achieve a well
It is the die in which two or more than two operations may guided movement of moving half of the tool to the fixed half
be completed at one station (cutting operation).This die is of press tool. In top plate bush are fitted and in between guide
considered as cutting dies in which different operations like pillar and bush have a sliding fit.
Piercing & blanking will take place at one station.

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ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 9, Issue 11, May 2020
Bottom plate: this is the base of press tool.it is made in Third stage: Fracture: Further continuation of punching
mild steel.the die at the pillar are fiited in the plate.this plate is pressure then material near the cutting edge of the punch and
fastened to the press bed. die become highly stressed. When the stress goes beyond the
Shunt height: It is the distance from top of the bed to the ultimate strength of material fracture start to arise at the
bottom of the slide with its stroke down and adjustment up. cutting edge of the punch and die. Under proper cutting
 Theory of shearing condition the fracture extend toward each other and meet.
The name shearing stands for method of cutting sheets When this occurs the fracture complete and blank /slug is
stock without forming chips. In blanking /piercing tool as the separated from the stock material. Slight burr will be formed
punch contact the stock material which over the die plate a along the top edge of the slug and the bottom edge of stock
pressure build up occur due to this excessive load when the material. Then punch enters the die opening slightly pushing
elastic limit exceeded the material flow plastically and punch the slug/blank slightly below cutting edge.
penetrate the stock material continuously blank or slug in to
the die opening. Further continuation of punching pressure IV. IMPLEMENTATION
causes the start of fracture at the cutting edge of punch and  Component Drawing
dies and on continuation the fracture meets and the stock is
sheared/cut. Shearing action consist three stages
First stage: plastic deformation: The pressure applied by
the punch on the stock material tends to deform it in to the die
opening. The strip is over the die plate and punch contacts the
stock material and exerts pressure up on the strip as the press
ram is forced down, as the elastic limit of the stock material is
exceeded plastic deformation take place. Due to this a radius
is formed on the top edge of the strip and the bottom edge of Fig: 4. 2 D and 3D Sketch
slug/blank .this radius is referred as roll over. Aluminum: Properties
Second stage:Penetration:As driving force of the ram
continues the punch is forced to penetrate the stock material Aluminum Alloy 6063
and the blank or slug is forcefully displaced in to die opening Shear strength: 207Mpa
a considerable amount compression of the slug material Young's Modulus: 69.5Gpa
against the wall of the die opening produces a highly shining Yield Strength: 240Mpa
portion on the edge of the blank/slug.At the same time the Density: 2.70g/cm3
plastic flow pull the material around the punch causing a Melting Point: 600 C
corresponding shining portion on the edge of the work stock Modulus of rigidity: 69.5Gpa
material .This is referred to as cut band. Which is Chemical Composition
approximately one third of thickness of stock material. Table 1: Chemical Composition

 Blanking Die Design

1. Blank size determination
2. Design of strip layout
3. Calculation of economic factor
4. Calculation of Cutting Force and Calculation of
stripping
5. Calculation of cutting clearance
6. Determination of punch and die size
7. Calculation of plate thickness Die plate, stripper
plate, punch holder, thrust plate
8. Checking punch for crushing
Fig: 3 Stages in Shearing 9. Calculation of critical buckling load and critical

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 ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 9, Issue 11, May 2020
length of punch Stock thickness=1.5mm
10. Calculation of deflection of punch
Cutting force= LxSxTmax
11. Calculation of deflection of die plate
1. Blank Size Determination =1.5x182.12X207
Calculation of d/r Ratio = 56548.26N
d=30mm r=3mm Stripping Force=20%cutting force
=30/3=10 = 56548.26x.20=11309.65N
d/r ratio between 10 and 15 5. Calculation of Cutting Clearance
Blank size D=√ d2+4dh-r Cutting clearance
=√ (30)2+ (4x20x30)-3 C=0.0032t√ts mm/side
=57.41mm t=sheet thickness=1.5mm
0.15 mm is added as trim allowance ts=207Mpa
Blank diameter=57.41+0.15=57.56=58mm
C=0.0032x1.5x√207=0.069mm per side
2 & 3. Design of Strip layout and Calculation of
6. Determination of Punch and Die Size
Economic factor
Economic factor not less than 70% Blanking Die size=Blank size=58mm
Blanking Punch size= (Blank size-Total clearance)
=58-(2X0.0690)
= 57.862mm
7. Calculation of Plate thickness Die plate, stripper plate,
punch holder, thrust plate
Die plate thickness = (cutting force) 1/3
= (56548.26) 1/3
=38.38=40mm
Fig 5: Strip Layout Punch holder plate thickness=0.75xthickness of die plate
Scrap bridge = T to 1.2 T =0.75x40=30mm
= 1.2 x1.5=1.8mm=2mm Thrust plate thickness =15 to20mm=15mm
Margin =1.25 to 1.5T Stripper plate thickness =0.5xdie plate
=1.5x1.5=2.25mm thickness=40x0.5=20mm
Economic Factor= (Area of blank x100xNo of 8. Checking Punch for Crushing
rows)/(pitch x width of strip) Cutting force = π/4 xd2x σc
Area of blank=πD2/4 56548.26 = π/4 x(57.862) 2x σc
= 3.14x (58) 2/4 56548.26 =2628.18x σc
= 2640.74mm 2
σc = 21.51N/mm2
Economic factor= (2640.74x100x1)/(60.5x62)=70.4% σc =21.51N/mm2<<<250N/mm2 Safe in crushing
4. Calculation of Cutting Force Slendness Ratio
Cutting force =LxSxTmax Compressive strength= 250N/mm2
L=Length of periphery to be cut in mm 250 = (π2E)/ (l/k) 2
S=Stock thickness in mm (l/k) 2= (3.142x200x103)/250
2
Tmax=shear strength of material N/mm (l/K)=88.81
Length of periphery to be cut= πD=3.14x58=182.12mm Slendness ratio greater than 80 Eulers formula for a mild
Tmax=207Mpa steel column is vali

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 ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 9, Issue 11, May 2020
9. Calculation of Critical Buckling Load and Critical =.0022089mm
Length of Punch  Modeling of Blanking Tool
Critical buckling force and critical length of punch
Pcr = (π2EI)/ (4L2)
I=Moment of inertia= (π /64) xd4
I= (π /64) x (58) 4
I=555215.58mm4
L=Longitudinal length of punch=50mm
Pcr = (3.14) 2x200x103x555215.58
4x (50) 2
=109484070.65N Fig 6: Modeling of Blanking Tool

Critical buckling load>>>Cutting force. Punch is safe from

buckling
Maximum length that can be used if applied load equal to
critical load with safety factor 4.
Lcr=√ (π2EImin)/4CP
= π2x200x 103 x555215.58
= √ 4x (4x56548.26)
=1100mm
Punch is safe from buckling because the punch length lower Fig 7: Exploded View Blanking Tool
than 1100mm. Unguided length of punch is 50mm with  FEM Analysis of Blanking Punch and Blanking Die
overall length of 80mm. Analysis of Blanking Punch
10. Calculation of Deflection of Punch Table: 2 Material data Blanking Punch
Deflection of blanking punch.
=FbL3/3EI
= (56548.26x503)/ (3x200x103x555215.58)
=0.02120mm
11. Calculation of Deflection of Die Plate
Compressive stress in blanking die
Mean compressive stress =Vertical force
Shearing area
Shearing Area= π/4 x (58)2=2640.74mm2 Table: 3 Load Constraints Blanking Punch
=
56548.26/2640.74 =21.41Mpa
Deflection of Die
Deflection of blanking die =FL3/192EI
F =80% cutting force
F = 0.8x56548.26
=45238.60N
L=100mm
I=bh3/12=100x (40)3/12=533333.3mm4.
=45238.60x (100)3)/(192x200x103x533333.3)

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 ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 9, Issue 11, May 2020
Table 7. Comparison between Analytical and FEM branch

 Drawing Die Design

1. Calculation of drawing force and blank holding
force
2. Calculation of no of stages, drawing ratio,
Consideration of strain factor, Limiting drawing
ratio
3. Determination of cupping factor, flow stress
4. Calculation of punch and dies size, punch radius
Table 4. Comparison between Analytical and FEM and die radius.
branch 5. Calculation of plate thickness Die plate, stripper
plate, punch holder, thrust plate
6. Checking punch for crushing
7. Calculate critical buckling load and critical
length of punch
8. Calculation of deflection of punch and die
1. Calculation of Drawing Force and Blank Holding Force
Table 5. Material Data Blanking Die Drawing force = d.t.s((D/d)-c)
D= Blank diameter=58mm
d=Punch diameter=30mm
t= thickness of sheet metal=1.5mm
S=yield strength of Aluminum=240Mpa
Drawing force = 58x1.5x240x ((58/30)-0.6)
=27770.4N
Table: 6 Load Constraints Blanking Die
Calculation of blank holding force
=1/3 Drawing force
=1/3x27770.4
=9256.8N
2. Calculation of No of Stages, Drawing Ratio,
Consideration of Strain Factor, Limiting Drawing Ratio
 Determination of no of stages
Draw ratio=h/D
0<h/d<0.75 simple draw
0.75<h/d<1.5 deep draw
h/d=20/30=0.666
0.666<0.75 simple draw or shallow draw
 Consideration of strain factor
The ratio h/H measure the tensile strain .the
recommended value of ratio for first draw is 1.4 for
aluminum alloy
ec=h/H
H=D-d/2=(58-30)/2=14

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 ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 9, Issue 11, May 2020
2 2 2 2 5. Calculation of Plate Thickness Die Plate, Stripper Plate,
h=D -d /4D= ((58) -(30) )/ (4X30) =20.53
Punch Holder, Thrust Plate
Die plate thickness= (Drawing force) 1/3 = (27770.4)1/3
h/H=20.53/14=1.46 =30mm
 Consideration of d/D ratio Stripper plate=0.5xDie plate thickness=0.5x30=15mm
Recommended value of d/D value for first draw for Punch holder plate=0.75xDie plate
aluminum 0.52 thickness=0.75x30=22.5mm
d/D=30/58=0.51 Thrust plate thickness=15mm
 Limiting drawing ratio 6. Checking Punch for Crushing
Limiting drawing ratio is defined as the maximum ratio  Checking for punch crushing

of blank sheet diameter to punch dia. Drawing force= π/4 xd2x σc

LDR=Dbmax/Dp 27770.4 = π/4 x (30)2x σc

=58/30=1.9 σc =39.30N/mm2

An approximate upper limit on the drawing ratio is a σc =39.30N/mm2 <<< 250 N/mm2 Safe in crushing

value of 2  Slendness ratio

 Draw reduction Compressive strength= 250N/mm2

For one draw the percentage reduction permissible is 250 = (π2E)/(l/k) 2

about 50% (l/k) 2= (3.142x200x103)/250

(l/K)=88.81

%reduction=((D-d)/D)x100=((58-30)/58)x100=48.27% Slendness ratio greater than 80 Eulers formula for a mild

So it is obivious that cup can draw in one draw. steel column is valid

3. Determination of Cupping Factor, Flow Stress 7. Calculate Critical Buckling Load and Critical Length of
Punch
 Calculation of cupping factor
Cupping strain factor € gives the actual strain in the metal  Critical buckling force

created by its elongation during drawing process Pcr = (π2EI)/ (4L2)

€ = ((D/d) +1)/2 I=Moment of inertia=( π /64)xd4

€ = ((58/30) +1)/2 I= (π /64) x (30) 4

=1.43 I=39740.62mm4

 Flow stress L=Longitudinal length of punch=60mm

σt = KƐn Pcr = (3.14) 2x200x103x39740.62

K=Modulus of rigidity=69.5Mpa 4x (50) 2

n=strain hardening coefficient=0.095 =5442036.347N

Ɛ=strain=1/2ln (D/d) =0.5xln (58/30) =0.067 Critical buckling load>>>drawing force. Punch is safe

σt = 69.5x0.0670.095=53.76Mpa from buckling

4. Calculation of Punch and Dies Size, Punch Radius and  critical length of punch
Die Radius Maximum length that can be used if applied load equal to
Punch diameter=30mm
critical load with safety factor 4.
Punch radius=3mm
Lcr=√ (π2EImin)/4CP
Die diameter=dp+2x (1.1t) =30+2x (1.1x1.5)=33mm
= π2x200x 103 x39740.62
Draw radius= 4to 10 times blank thickness=6x1.5=9mm
√ 4x (4x27770.4)

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International Journal of Engineering and Innovative Technology (IJEIT)
Volume 9, Issue 11, May 2020
=419.96mm
Punch is safe from buckling because the punch length lower
than 419.96mm. Unguided length of punch is 60mm with
overall length of 80mm.
8. Calculation of Deflection of Punch and Die
 Deflection of Punch
Deflection of drawing punch.
=FbL3/3EI
= (27770.4x603)/(3x200x103x39740.62)
=0.25156mm
 Compressive stress in drawing die
Mean compressive stress =Vertical force
Drawing area
Shearing Area= π/4 x (33) =854.865mm2
2
 FEM Analysis of Drawing Punch and Drawing Die
Table: 8 Material Data Drawing Punch
=27770.4/
854.865 =32.48Mpa
 Deflection of Die
Deflection of blanking die
=FL3/192EI
F=80% drawing force
F= 0.8x27770.4
Table: 9 Load constraints drawing punch
=22216.32N
L=100mm
I=bh3/12=100x (30)3/12=225000m4.
= (22216.32x100)3)/(192x200x103x225000)
=00257mm
 Modeling of Drawing Tool

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 ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 9, Issue 11, May 2020
Table 10. Comparison between Analytical and FEM  Component
branch

Table 11.Material data Drawing Die

Table: 12 Load constraints Drawing Die

Fig 15: Strip Blank and Cylindrical Cup

 Cause and Effect Diagram for Wrinkling

Fig 16. Cause and Effect diagram for wrinkling

V.CONCLUSION
Table 13. Comparison between Analytical and FEM
branch In this work some significant aspects of press tool design
for cylindrical cup is discussed and also detailed study and
analysis were carried out. By implementing computer in
design accuracy of design is improved and design process
time is reduced drastically than by traditional method. Punch
 Development of Blanking Tool and Drawing Tool
and die analysis of the tool were carried out and the design
found to be safe. Results obtained through analysis are
approximately nearer to the theoretical value. Cause effect
diagram is used to clearly understand parameter which
effecting wrinkling defect.

VI.FUTURE WORK
CAE plays very significant role in the decision making of
various parameter of sheet metal forming processes and it
helps to designer during product design as well as tool design
stage to decide optimum and accurate process parameter.CAE
software such as Hyper form, FEA used for formability
Fig 14: Blanking Tool and Drawing Tool analysis and prediction of wrinkles. The effect of various

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 ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 9, Issue 11, May 2020
parameter that cause wrinkling defect can be determined
using statically as well as experimental method. Mr. Ajmal Roshan P.P Final year B-tech student in the
mechanical Engineering Department at AWH Engineering
REFERENCES College Calicut Kerala India
[1] B hagyashri Billade Prof. Sachine Dahake. ”Design and
analysis of Draw bead profile in sheet metal forming of rein
–rfend upr-lh/rh for safe thinning” IJESI Volume 7 Issue 7.
[2] Fissa Biruke Teshome Yonas Mitiku Degu. ”Design of
combined press tool for the manufacturing of rise thresher Mr. Akshay. K Final year B-tech student in the mechanical
blade”THE IJES Volume 3 Issue 4 2014. Engineering Department at AWH Engineering College Calicut
[3] Vyshakh Sannamani L G Dr Ramegowda D. ”Design analysis Kerala India
of punch and die for blanking piercing and forming tools to
produce chain guide mounting bottom bracket”IJIMINDS
Volume 3 Issue 8 2016 .
[4] Abhijit Ajabrao Tagade Nilesh Nirwan”Design and
manufacturing of compound press tool for washer”IJSR
Volume 5 Issue 8 August 2016.
[5] Gaurav C Rathod Dr D Raut. Study and analysis of press tool
design” ijert Volume 6 Issue 7 2017.

AUTHOR BIOGRAPHY

Mr. Jibi. R Received M-tech in Production and

Industrial Engineering from SCMS School of
Engineering and Technology Ernakulum Kerala in
2013.Recieved B-tech Degree in Mechanical
Engineering from CUIET Malappuram Kerala in
2011 and Diploma in Tool and Die Making from
KELTRAC Alappuzha in 2008.He has published
Seven International journals and presented two articles in International
conference. He has more than seven years experience in teaching and one
year Industrial experience in Press tool and Mold making. His interested area
is computer aided design and analysis, Production Technology and
Industrial Hydraulics. Currently he is working as an Assistant Professor in
the mechanical engineering department at AWH Engineering College
Calicut Kerala India.

Mr. Thejas.S Final year B-tech student in the mechanical

Engineering Department at AWH Engineering College Calicut
Kerala India

Mr. Vaishnav.N Final year B-tech student in the mechanical

Engineering Department at AWH Engineering College Calicut
Kerala India

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