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Determination of LDR in Deep Drawing Process by
Reduced Number of Experiments

A C S Reddy1 , Dr. S. Rajesham2
1 Research
Scholar,Dept of Mechanical Engineering, O U

2 Visiting Professor, IIIT-Basara
9th December 2016
International Conference on Advances in Materials & Manuracturing

December 8-10, 2016
Hyderbad , INDIA
()
CONTENTS
Contents
F Introduction
()
CONTENTS
Contents
F Introduction
F Literature review
()
CONTENTS
Contents
F Introduction
F Literature review
F Methodology
()
CONTENTS
Contents
F Introduction
F Literature review
F Methodology
F Deep Drawing Tool setup developed
()
CONTENTS
Contents
F Introduction
F Literature review
F Methodology
F Experimental tests
()
CONTENTS
Contents
F Introduction
F Literature review
F Methodology
F Results discussion
()
CONTENTS
Contents
F Introduction
F Literature review
F Methodology
F Conclusions
()
CONTENTS
Contents
F Introduction
F Literature review
F Methodology
F Conclusions
F Acknowledgments
()
CONTENTS
Contents
F Introduction
F Literature review
F Methodology
F Conclusions
F Acknowledgments
F References
()
Introduction
Light weight sheet metals & Deep Drawing
F Light weight sheet metal applications are;
()
Introduction
F Increasing in present days in aerospace, automotive and other industrial
sector
()
Introduction
sector
F In reducing fuel consumption and emission of hazardous exhaust gases
as well.
()
Introduction
sector
as well.
F Aluminum, Magnesium and other light metals are highly used in the
production of automobile fuel tanks, beverage tanks etc.
()
Introduction
sector
as well.
F Deep Drawing &LDR

F Deep drawing is a drawing operation where the depth of the cup
produced is at least equal to the diameter of the cup
()
Introduction
sector
as well.
F Deep Drawing &LDR

F The deep drawing process may involves multi step deep drawing
operation.
()
Introduction
sector
as well.
F Deep Drawing &LDR

operation.
F The maximum size of the blank successfully drawn or number of steps in
incremental deep drawing purely depends on LDR.
()
Introduction
sector
as well.
F Deep Drawing &LDR

operation.
F What is LDR
()
Introduction
sector
as well.
F Deep Drawing &LDR

operation.
F What is LDR
()
F LDR is is the ratio of maximum size of the blank used for successful
draw to the punch diameter.
Introduction
CONCEPT OF L D R
F The traditional method of finding LDR is by gradually increasing the
diameter of the blank in deep drawing till finding the maximum
successful blank size.
()
Introduction
CONCEPT OF L D R
F This traditional method needs so many tests consuming more material,
time and cost.
()
Introduction
CONCEPT OF L D R
time and cost.
F The developed method through this research needs only three test for
finding LDR.
()
Introduction
CONCEPT OF L D R
time and cost.
finding LDR.
F It requires only two blanks of undersize and one blank of oversize.
()
Introduction
CONCEPT OF L D R
time and cost.
finding LDR.
F The experimental tests conducted with 100 mm, 140 mm and 200 mm
diameter blanks
()
Introduction
CONCEPT OF L D R
time and cost.
finding LDR.
F The experimental tests conducted with 100 mm, 140 mm and 200 mm
diameter blanks
F The simulation tests also conducted for validation the results and
proved satisfactory by this proposed method.
()
LITERATURE REVIEW
Literature review
F From literature found that the maximum punch load is proportional to
blank sizea
a
Jain, M., J. Allin, and M. J. Bull. "Deep drawing characteristics of automotive aluminum alloys." Materials
Science and Engineering: A 256.1 (1998): 69-82
b
Behrens, G., et al. "Influence of tool geometry variations on the limiting drawing ratio in micro deep drawing."
International Journal of Material Forming 9.2 (2016): 253-258.
c
Fan, Xiao-bo, et al. "Formability and strengthening mechanism of solution treated AlMgSi alloy sheet under
hot stamping conditions." Journal of Materials Processing Technology 228 (2016): 179-185.
()
LITERATURE REVIEW
Literature review
blank sizea
F LDR increases with increase in die shoulder radius in micro deep
drawingb
a
b
c
()
LITERATURE REVIEW
Literature review
blank sizea
F LDR increases with increase in die shoulder radius in micro deep
drawingb
F The deep drawing tests conducted by Xiao-bo Fan et.alc show that the
limiting drawing ratio increased as temperature increases up to 200o C
and decreased afterwards for the magnesium alloy and the
corresponding LDR was 1.9.
a
b
c
()
LITERATURE REVIEW
Literature Review
F The LDR varies with die shoulder radius and found asa 1.33 and 3.21
for sharp die shoulder radius and round die shoulder radius respectively
a
Pourboghrat, Farhang, Senthilkumar Venkatesan, and John E. Carsley. "LDR and hydroforming limit for deep
drawing of AA5754 aluminum sheet." Journal of Manufacturing Processes 15.4 (2013): 600-615.
b
Ma, Wen-yu, et al. "Influence of process parameters on deep drawing of AA6111 aluminum alloy at elevated
temperatures." Journal of Central South University 22 (2015): 1167-1174
c
Lucian Lazarescu, Ioan Nicodim, and Dorel Banabic. Evaluation of drawing force and thickness distribution in
the deep-drawing process with variable blank-holding. In Key Engineering Materials, volume 639, pages 33. Trans
Tech Publ, 2015.
()
LITERATURE REVIEW
Literature Review
F Punch velocity, blank holder force (BHF), friction coefficient and
forming temperature influences for minimum thickness and blank
holder force has greatest influence on it in sheet hydro-formingb
a
b
c
Tech Publ, 2015.
()
LITERATURE REVIEW
Literature Review
F Punch velocity, blank holder force (BHF), friction coefficient and
forming temperature influences for minimum thickness and blank
holder force has greatest influence on it in sheet hydro-formingb
F Variable blank holding force in deep drawing has reduced the drawing
forcec
a
b
c
Tech Publ, 2015.
()
LITERATURE REVIEW
Literature Review
F The study conducted by Demirci et.ala , revealed that no earing and
wrinkling found in BHFs between 1.3 and 8 MPa in square deep
drawing process and that tears occurred over 18 MPa.
a
Demirci, Halil Ibrahim, Cemal Esner, and Mustafa Yasar. "Effect of the blank holder force on drawing of
aluminum alloy square cup: Theoretical and experimental investigation." Journal of materials processing
technology206.1 (2008): 152-160.
b
Reddy, A. C. S., S. Rajesham, and P. R. Reddy. "Experimental and simulation study on the warm deep drawing
of AZ31 alloy." Advances in Production Engineering & Management 10.3 (2015): 153.
()
LITERATURE REVIEW
Literature Review
F The study conducted by Demirci et.ala , revealed that no earing and
wrinkling found in BHFs between 1.3 and 8 MPa in square deep
drawing process and that tears occurred over 18 MPa.
F The study conducted by Reddy et.alb on drawability of magnesium
alloy found that limiting drawing ratio (LDR) increased significantly
with increase in temperature and maximum at 300o C.
a
Demirci, Halil Ibrahim, Cemal Esner, and Mustafa Yasar. "Effect of the blank holder force on drawing of
aluminum alloy square cup: Theoretical and experimental investigation." Journal of materials processing
technology206.1 (2008): 152-160.
b
Reddy, A. C. S., S. Rajesham, and P. R. Reddy. "Experimental and simulation study on the warm deep drawing
of AZ31 alloy." Advances in Production Engineering & Management 10.3 (2015): 153.
()
Tool Design Setup

Components of tool setup
F The design of deep drawing tool setup is a highly specialized task.
()
Tool Design Setup

F It consists of number of important activities that sequentially starts
with determination of blank size, selection of process parameters and
tool parameters.
()
Tool Design Setup

tool parameters.
F The components of deep draw tool setup are die, punch, dieholder,
blank holder and punch holder.
()
Tool Design Setup

tool parameters.
F The components of deep draw tool setup are die, punch, dieholder,
blank holder and punch holder.
F The blank holder load can be varied by applying the compressive force
over the open coiled helical spring housed over the blank holder by
means of tightening the nut provided for it.
()
METHODOLOGY
Testing parameters used
F The deep drawing setup developed and tests are conducted with the
use of Universal testing machine which is having having computerized
recording system for punch load and punch displacement.
()
METHODOLOGY
F The tool parameters used in tool setup are
Die profile radius: 5.5 mm
Punch nose radius of 5.5 mm and
Blank holder force of 7 kN.
()
METHODOLOGY
F The tool parameters used in tool setup are
Die profile radius: 5.5 mm
Punch nose radius of 5.5 mm and
Blank holder force of 7 kN.
F The blank sizes used while keeping all other parameters unchanged are
100 mm,
140 mm and
200 mm are used for draw tests while keeping all other tool and
processes parameters remains unchanged.
()
Deep Draw Tool Setup Developed

Deep Draw Tool
F The blanks were prepared from the aluminum (commercial grade)
sheet of 0.9 mm thickness.
()
10

Deep Draw Tool
F The exact sizes of blanks were prepared by cutting from sheet by laser
cutting. The laser cut blank have no burrs and avoids stress
concentration leading to failure by wrinkling while drawing.
()
10

Deep Draw Tool
F The exact sizes of blanks were prepared by cutting from sheet by laser
cutting. The laser cut blank have no burrs and avoids stress
concentration leading to failure by wrinkling while drawing.
()
10
EXPERIMENTS
Experimental works
F Experimental tests were conducted for recording punch force vs. punch
displacement readings
Test results for 100

mm blank
()

mm blank

mm blank
11
EXPERIMENTS
Experimental works
F Experimental tests were conducted for recording punch force vs. punch
displacement readings

mm blank

mm blank

mm blank
F Drawn cups with 100mm, 140 mm and 200 mm blank diameter
()
11
EXPERIMENTAL TESTS
Experimental results
F Maximum punch load vs. blank diameter graphs were plotted and
found critical diameter as given below.
Experimental Test Results
()
Simulation Test Results
12
EXPERIMENTAL RESULTS
F The maximum punch load for each test recorded is also show in Table .
()
13
EXPERIMENTAL RESULTS
F The maximum punch load for each test recorded is also show in Table .
F The simulation tests also have been conducted and recorded.
Test results
()
13
DISCUSSION
RESULTS AND DISCUSSION

F The critical blank diameter found from simulation tests is 145.20 mm.
()
14
DISCUSSION

F The critical diameter found from experimental results is 140.05 mm.
The LDR for simulation is 1.85.
()
14
DISCUSSION

F The critical diameter found from experimental results is 140.05 mm.
The LDR for simulation is 1.85.
F The LDR for experiments is 1.75 with an acceptable error of 5.4% in
comparison to simulation results. This variation may be due to
variation in friction conditions selected for simulation.
()
14
CONCLUSIONS
Conclusions
F It is concluded that the punch load is proportional to blank diameter
both in experimental and simulation study.
()
15
CONCLUSIONS
Conclusions
F It is concluded that the LDR found in experiments is in good
agreement with simulation results.
()
15
CONCLUSIONS
Conclusions
F It is concluded that the LDR found in experiments is in good
agreement with simulation results.
F This concept can be used to test LDR for different input parameters
for validation of the load proportionality with blank size below LDR
and constant for oversized blanks.
()
15
ACKNOWLEDGEMENTS
Acknoledgements
F The author is very much thankful to HOD and faculty, Department of
Mechanical Engineering, Osmania University for continuous support in
developing research skills and especially in communicating all research
programs, conferences, etc., taking place at O.U.
()
16
ACKNOWLEDGEMENTS
Acknoledgements
F Author expresses heartfelt thanks to Dr. P Ravinder Reddy HOD, CBIT
()
16
ACKNOWLEDGEMENTS
Acknoledgements
F Author expresses heartfelt thanks to Dr. P Ravinder Reddy HOD, CBIT
F The author is also thankful to Dr. Suresh Akella, Principal, Sreyas
Engineering College for his guidelines in doing the research work.
()
16
REFERENCES
References
1 Jain, M., J. Allin, and M. J. Bull. "Deep drawing characteristics of
automotive aluminum alloys." Materials Science and Engineering: A
256.1 (1998): 69-82.
()
17
REFERENCES
References
256.1 (1998): 69-82.
2 Behrens, G., et al. "Influence of tool geometry variations on the
limiting drawing ratio in micro deep drawing." International Journal of
Material Forming 9.2 (2016): 253-258.
()
17
REFERENCES
References
256.1 (1998): 69-82.
3 Fan, Xiao-bo, et al. "Formability and strengthening mechanism of
solution treated AlMgSi alloy sheet under hot stamping conditions."
Journal of Materials Processing Technology 228 (2016): 179-185.
()
17
REFERENCES
References
256.1 (1998): 69-82.
4 Pourboghrat, Farhang, Senthilkumar Venkatesan, and John E. Carsley.
"LDR and hydroforming limit for deep drawing of AA5754 aluminum
sheet." Journal of Manufacturing Processes 15.4 (2013): 600-615.
()
17
REFERENCES
References
256.1 (1998): 69-82.
4 Pourboghrat, Farhang, Senthilkumar Venkatesan, and John E. Carsley.
"LDR and hydroforming limit for deep drawing of AA5754 aluminum
sheet." Journal of Manufacturing Processes 15.4 (2013): 600-615.
()
5 Ma, Wen-yu, et al. "Influence of process parameters on deep drawing

of AA6111 aluminum alloy at elevated temperatures." Journal of
Central South University 22 (2015): 1167-1174.
17
REFERENCES
References
6 Lucian Lazarescu, Ioan Nicodim, and Dorel Banabic. Evaluation of
drawing force and thickness distribution in the deep-drawing process
with variable blank-holding. In Key Engineering Materials, volume 639,
pages 33. Trans Tech Publ, 2015.
()
18
REFERENCES
References
7 Demirci, Halil Ibrahim, Cemal Esner, and Mustafa Yasar. "Effect of the
blank holder force on drawing of aluminum alloy square cup:
Theoretical and experimental investigation." Journal of materials
processing technology206.1 (2008): 152-160.
()
18
REFERENCES
References
8 Reddy, A. C. S., S. Rajesham, and P. R. Reddy. "Experimental and
simulation study on the warm deep drawing of AZ31 alloy." Advances
in Production Engineering & Management 10.3 (2015): 153.
()
18
REFERENCES
References
8 Reddy, A. C. S., S. Rajesham, and P. R. Reddy. "Experimental and
simulation study on the warm deep drawing of AZ31 alloy." Advances
in Production Engineering & Management 10.3 (2015): 153.
9 Reddy, A C Sekhara, S. Rajesham, and P. Ravinder Reddy.
"Experimental Study on Strain Variation and Thickness Distribution in
Deep Drawing of Axisymmetric Components." International Journal of
Engineering 2.12 (2013).
()
18
()
19

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Determination of LDR in Deep Drawing Process by

Reduced Number of Experiments

Scholar,Dept of Mechanical Engineering, O U

9th December 2016

International Conference on Advances in Materials & Manuracturing

F Deep Drawing &LDR

F Deep Drawing &LDR

F Deep Drawing &LDR

F Deep Drawing &LDR

F Deep Drawing &LDR

Tool Design Setup

Tool Design Setup

Tool Design Setup

Tool Design Setup

Deep Draw Tool Setup Developed

Deep Draw Tool Setup Developed

Deep Draw Tool Setup Developed

Test results for 100

Test results for 140

Test results for 200

Test results for 100

Test results for 140

Test results for 200

F Drawn cups with 100mm, 140 mm and 200 mm blank diameter

Experimental Test Results

Simulation Test Results

RESULTS AND DISCUSSION

RESULTS AND DISCUSSION

RESULTS AND DISCUSSION

5 Ma, Wen-yu, et al. "Influence of process parameters on deep drawing

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