Deep Drawing: Benefits And Industrial Applications
Deep drawing is one of the most popular metal forming methods available to manufacturers - it involves forming a metal slab into a desired shape using a metal die. Specifically, if the depth of the created item is equal to or greater than its radius, then the metal forming process can be referred to as deep drawing.
Deep drawing process
The deep drawing forming process begins with a metal blank. Often, individual blanks are used to facilitate the creation of parts or products with a deeper shape. Sometimes, these metal blanks will be placed on a spool to allow the metal to be formed efficiently. In each step of the deep drawing process, the metal blanks are formed by the pressure applied by the metal die.
Custom Precision Deep Drawing Parts
Although deep drawing is similar to metal stamping, these terms are not interchangeable. A press does not leave a machine until the metal is fully formed. Typically, deep drawing is used to create parts and products that are deeper than metal stampings.
The formability limitations of traditional deep drawing are a barrier to certain industrial uses. Radial tensile stresses and tangential compressive stresses are common problems that can lead to wrinkling, fracture or cracking in some applications. A number of unconventional drawing techniques have been implemented recently that have helped increase the industrial use of drawing. These processes include hydroforming, hydromechanical deep drawing, water deep drawing, hydraulic deep drawing, the Guerin process, and the Marform process.
Almost all manufacturing industries have the potential to benefit from deep-drawing manufacturing processes. The technology is probably best suited for manufacturing small parts such as electronic relays, solenoids and assembly housings. However, products of all shapes and sizes can be economically manufactured by this process, including items such as aluminum cans, cookware and kitchen sinks.
Deep Drawing Parts
Benefits of deep drawing
Deep drawing is particularly useful in high-volume production because unit costs decrease significantly as unit quantities increase: once the tool and die are created, the process can continue with little downtime or maintenance. Tooling is less expensive to manufacture than similar manufacturing processes, such as progressive die stamping, even at smaller volumes; in these cases, too, deep drawing may prove to be the most cost-effective manufacturing solution.
When considering the functionality of the final product, deep drawing offers additional advantages. Specifically, the technique is well suited for products that require significant strength and minimal weight. The process is also recommended for product geometries that cannot be achieved through other manufacturing techniques.
Deep drawing may be most useful for creating cylindrical objects: round metal blanks can be easily drawn into 3D round objects with a single stretch ratio, thus minimizing production time and costs. The production of aluminum cans is an example of the widespread use of this method.
Squares, rectangles and more complex geometries may create slight complexity, but can still be easily and efficiently created by the deep drawing process. Typically, as the complexity of the geometry increases, the number of stretch ratios and production costs increase.
Deep drawing may be a viable production solution for any manufacturing process that requires one or more of the following.
Seamless parts: deep drawn parts made from a single sheet of metal
Fast cycle times: large quantities are easily manufactured by deep drawing
Complex axisymmetric geometries: deep drawing provides excellent detail and accuracy
Reduced skilled labor: precision deep drawing provides similar results to skilled labor in faster time
