Deep Drawing Process

Reduction of Wrinkling Defect in Deep Drawing Process

Abstract. The aim of this experiment is to obtain the best parameters for reducing wrinkle defect during deep drawing process. Deep drawing is a sheet metal forming process where a punch is utilized to force a flat sheet metal to flow into the gap between the punch and die surfaces. Due to that, the sheet metal will deformed into the desired shape. Some of the most common outcomes in deep drawing process are tearing and wrinkling or the formation of uneven height at the top rim of a drawn part due to the material anisotropy. Wrinkling as become a serious obstacle to forming quality and part functions and finally results in scraps. This defects are caused due to change in parameters like

At first, sheet metal was cut into the required shape and placed on the die. Punch is fixed on the top of machine which give compressive force on the sheet metal. Due to high compressive force, the sheet metal was deformed into the shape of die [1,2,3]. During deep drawing process, if the force acting on the sheet metal is more, the wrinkling defect will occur in the finished component. It is found that wrinkling occur due to improper punching speed also. Hence, in order to reduce the defect and improve the quality of product [4,5]. Deep drawing was done with different parameters and the suitable parameter was found for drawing

Copper is widely used in the manufacture of important alloys such as brass and bronze. It is a ductile metal with very high thermal and electrical conductivity [6,7,8]. Deep drawing steel is more ductile than commercial quality and is suitable for producing deep drawn parts needing severe deformation. It is not as formable as the extra deep drawing steel, but it is less costly. This material offers more formability to produce parts with a moderate depth of draw [9]. At first, the sheet metal of 1mm thickness is cut into the dimension 100x100 mm and then made as circular of diameter 90 mm as shown in figure.

Fig. sheet metal for deep drawing

2.1 Deep drawing die

The radius of the draw die should permit full freedom of metal flow as it passes over the radius. The draw ring causes the metal to begin flowing plastically and compressing the outer portion of the blank. However, if the draw radius is too large, the metal will be released by the blank holder and wrinkling will occur [10,11]. Sharp radius will hinder the normal flow of the metal and cause uneven thinning of the cup wall, which result in erring.

Fig. Deep Drawing Die

2.2 Deep Drawing