Deep drawing is a sheet metal forming process that uses a punch and die to pull (pull) a piece into a desired shape. The metal plate is placed between the two dies and the punch is pressed against it to create the desired profile. Deep drawing is used to make cups, bowls and other hollow shapes from sheet metal. It is also used to produce precision parts with complex shapes.
The deep drawing process uses hydraulic or mechanical presses. Although hydraulic presses are more powerful and can produce deeper stretching parts, hydraulic presses require much more space than mechanical presses.
The deep drawing process starts with the selection of a suitable blank larger than the finished part. The Deep Draw Stamping blank is placed between two dies and the die is closed so that the blank is pulled into the die cavity. The mold opens and the part pops out of the mold cavity.
Several factors can affect the quality of deep drawn parts.
1) Depth of mold cavity
The deeper the cavity, the greater the deformation and the better the parts. However, deeper molds are more expensive to make.
Different materials have different degrees of stiffness, porosity and elasticity. For example, steel is very hard, while aluminum is more elastic, so they deform differently during deep drawing. This must be taken into account when selecting materials for a particular application.
3) Mold design
There are many factors that affect the design of the die, including the number of cavities used, the draft allowance, the uniformity of the wall thickness, and the control of the lip diameter. Depending on the application, precise tolerances may be required.
4) Mold lubrication
Lubricant should be used as required – never too little or too much. A good mold lubricant will help achieve the desired results.
5) Mold tempering
Die tempering strengthens the die so that it does not deform during deep drawing.
6) compression force
The greater the compression force, the better the quality of the part. However, you must be careful not to apply too much, as this may damage the blank or cause the die to fail.
7) Drawing speed
A slow drawing speed results in high quality parts. Slower speeds give the material more time to flow and deform. On the contrary, high speed wire drawing will lead to die failure.
High top force can cause damage to parts or molds. The JACKING FORCE MUST BE SET TO a level SUFFICIENT TO EJECT THE PART FROM THE MOLD cavity, BUT NOT EXCEEDING THIS LEVEL.
9) Strip thickness
Thick strips are more difficult to pull than thin strips because there is more material to deform and less room for error. Using thick strips requires greater precision in the manufacturing process.
10) Blank outline
The profile or shape of the blank can affect the quality of the deep drawn parts. For example, blanks with sharp corners are more difficult to pull than those with rounded corners. The corner is prone to tear and malfunction in the process of wire drawing.
Deep draw stamping has many benefits.
Increase the intensity
The deep drawing process increases the strength of the workpiece by stretching the metal, pushing it in all directions, which helps to spread the stress evenly. This results in a more robust component that is less likely to fail under pressure.
Increasing the thickness of the
The deep drawing process increases the thickness of the workpiece because the metal is compressed as it is pulled into the die. The resulting increased thickness improves the strength and stiffness of the part.
To improve efficiency
The deep drawing process is more efficient than other processes, such as bending or rolling. Deep rafa doesn’t produce a lot of waste, which helps keep costs down.
A complex shape
Deep stretching can produce complex shapes because it doesn’t require a lot of material. This allows parts to be shaped with strict tolerances and minimal wall thickness variation.
Flexibility of design
Deep stretching allows designers to create complex features that are not possible in other sheet metal forming processes. This includes thin ranges, as well as well-designed internal ribs or pockets. In addition, different metals can be used in various parts of the parts. Molds can be designed with other metals, such as steel and brass.
Diversity of applications
Deep rafa is used in various industries to create a wide variety of products, from lollipops to muffin cups to auto parts and medical devices. Applications are only limited by the designer’s imagination.
Improve the quality
The deep drawing process gives the parts a consistent geometry and smooth surface, making the finished product more beautiful. Compared to other sheet metal forming processes, the deep drawing process excels in creating precisely shaped parts without the need for secondary finishing operations.
Low maintenance cost
Deep drawing components can reduce production costs because they do not require secondary processing, such as welding or machining, to achieve the finished product. In addition, the deep drawing process is a relatively low maintenance process that does not require extensive operator supervision.
Prolong parts of life
Deep drawing parts have a longer service life than parts manufactured using other sheet metal forming processes. The deep drawing process produces reliable and durable parts. Parts that withstand heavy loads or constant wear will benefit from the longer life of deep drawn parts.
The deep drawing process is environmentally friendly because it does not produce large amounts of waste. In contrast, other sheet forming processes often produce large amounts of scrap metal that must be recycled or properly disposed of.
Ease of use
The deep stretching process is simple and requires minimal training. In addition, the deep drawing process produces a variety of parts with complex geometric shapes using less material than other sheet metal forming processes. This makes deep rafting a very effective and cost-effective method.
The deep drawing process produces a uniform geometry and a consistent size every time. All parts have the same surface finish and performance characteristics, resulting in a more reliable product for the consumer.
Improve production efficiency
The deep drawing process can increase productivity by allowing manufacturers to make more parts in less time. This is because of the simple nature of the process, which does not require long operational training and extensive experience.
High quality parts
The deep drawing process produces high-quality parts with tight tolerances that require little additional finishing operations. This means that in most cases the parts can be shipped directly to the customer without the need for further manufacturing processes.