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fr Werkzeugmaschinen
und Betriebslehre
Lehrstuhl fr Technologie
der Fertigungsverfahren
Manufacturing Technology II
Exercise 5
Drawing Processes
Werkzeugmaschinenlabor
Lehrstuhl fr
Technologie der Fertigungsverfahren
Prof. Dr. - Ing. F. Klocke
RWTH - Aachen
Steinbachstrae 53
52065 Aachen
Inhaltsverzeichnis
Table of Contents
1 Introduction .................................................................................................... 3
2 Collection of formulas..................................................................................... 4
3 Exercises........................................................................................................ 5
3.1 Deep drawing......................................................................................... 5
3.2 Ironing.................................................................................................... 7
3.3 Stretch drawing...................................................................................... 9
Fertigungstechnik II - bung 5
Introduction
1 Introduction
The majority of thw work undertaken nowadays in the steel processing industry, is
in the field of sheet metal working. Sheet metal working processes are used in
order to manufacture three-dimensional parts from the sheet steel. The processes
most frequently used, are deep drawing, ironing , stretch drawing and bending.
The area of applications in deep drawing operations ranges from straightforward
cup-shaped components to complex free-form or sculptured parts like those used
in the automotive industry. Tool costs account for a large percentage of the
manufacturing cost. Consequently, deep drawing is used mainly for mass
production.
Ironing is used for axial tapering operations conducted on parts, generally
produced in a deep drawing operation. One example of the application of this
technique, is in the production of drinks cans.
In contrast, stretch drawing and bending processes rarely depend on the tools
used. They require a high level of manual use and are therefore used mainly for
form drawing in small series production.
However, all of the operations are very similar in terms of the states of stress
which produce plastic form change. The methods used to calculate forming forces
and deformation work, which form the basis of process and machine design, can
therefore be described together.
Fertigungstechnik II - bung 5
Collection of formulas
2 Collection of formulas
Vertical anisotropy:
b
ln 0
b1
r= b =
s
s
ln 0
s1
r=
FZ max = d1 s0 Rm K
1
(r + 2r45 + r90 )
4 0
Fn = AN pN
operations:
d
FZid = d m s0 k fm ln
dm
uZ = s0 + K 10 s0
operations:
Fertigungstechnik II - bung 5
Exercises
3 Exercises
3.1 Deep drawing
blank holder
s0
punch
sheet metal
drawing die
Fig. 3.1: Principle underlying deep drawing
A cylindrical cup without a flanged shoulder is to be deep drawn from a flat circular
blank in one draw.
Drawing ratio:
= 1,9
Cup diameter
(punch diameter):
dst = 70 mm
Initial thickness:
s0 = 1 mm
rR = 6 mm
Rm = 340 N/mm
1. The dimensions specified, necessitate the use of a clamp for holding down the
sheet steel required in order to prevent wrinkling. The rounding of the punch
edge and the change in the thickness of the sheet steel can be ignored in this
calculation.
2. Calculate the initial diameter of the circular blank d0
3. Calculate the height of the drawn part, h
4. The flange area of the sheet steel acted upon by the blank holder, is
AN = 7400 mm before forming begins.
Fertigungstechnik II - bung 5
Exercises
double-acting
single-acting
max. load:
blank holder tappet
10 kN
drawing tappet
80kN
80kN
100 kN
50 mm
70 mm
70 mm
press stroke:
Investigate the suitability of these machines for the machining tasks in hand.
Assume that the drawing force is the maximum value determined in Item 6.
Fertigungstechnik II - bung 5
Exercises
3.2 Ironing
D0
punch
D1
Di
Fertigungstechnik II - bung 5
Exercises
Cup diameter:
d1 = 100 mm
s1 = 2.5 mm
s2 = 1.6 mm
Forming efficiency
F = 0.4
Fertigungstechnik II - bung 5
0,252
kf () = 690
N/mm
Exercises
block as shown in
l0 = 1250 mm
b = 800 mm
s0 = 3 mm
Fertigungstechnik II - bung 5
Exercises
Forming efficiency:
F = 0.7
Extension required:
l1 - l0 = 350 mm
0,252
kf () = 690
N/mm
Fertigungstechnik II - bung 5
= 0
10