Deep Draw Metal Stamping for Strength and Efficiency
The deep drawing sheet metal forming process is a cold-forming metal fabrication process that is conducted in a room-temperature environment. A metal blank is stretched around a die cavity, eventually conforming to the shape of the plug, shape of the die, and the depth of the draw. This process is ideal for applications that require their depth to be greater than their radius, with excellent ductility, durability, and structural integrity. Because of work hardening and material thickening that takes place during material flow through the forming process, deep draw metal stamping is the ideal process for applications being placed in harsh environments or used for heavy-duty jobs. Common materials used for deep drawing are stainless steel, CRS, aluminum, copper, and brass. Typical shapes that result from the draw are housings, enclosures, cups, or domes. There are many benefits to the deep drawing process, two key items being the strength of the parts produced, and the efficiency of the process.Â
Deep Draw Stamping: Durable & Long-Lasting Parts
High precision deep drawn parts exhibit enhanced structural integrity due to work hardening, the process in which the metal’s structure is compressed and stretched during the forming process, where material flow is controlled to gradually form over the die and plug.
Deep drawn metal stamped parts formed seamlessly from a single metal blank, resulting in a finished shape with fewer potential failure points and without weak joints that may occur with secondary forming processes such as welding. Deep drawn parts may be long and narrow cylindrical housings, with length significantly greater than its outside diameter. Being seamlessly constructed enhances its structural integrity, giving deep drawn parts superior load-bearing capabilities, while making them ideal for heavy-duty applications for demanding industries like Oil and Gas, Aerospace, and Marine environments.
Deep drawn seamless shapes with no welds enhances smoother product flow and enables the option of adding water-tight or airtight seals. These characteristics make deep drawn parts advantageous in food processing, plastics, and material handling systems. Their seamless design enables a leak-proof performance and allows for easy cleaning and sanitization when required.
Work Hardening: How Deep Drawing Increases Strength
Work hardening is a process where the metal becomes stronger and harder through plastic deformation, specifically during cold forming processes like deep drawing. This occurs around room temperature, below the material’s recrystallization temperature.
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The recrystallization temperature is defined as the lowest temperature at which new, defect-free grains form and replace the existing deformed ones within a specifed time period. For most metals, this temperature ranges from around 30% to 50% of the metal’s melting point.
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Understanding work hardening is essential in deep drawing because the process truly changes the metal’s structure without altering its chemical composition. The applied mechanical stress of the forming process permanently deforms the material. Resulting in increased hardness, improved durability, also oftentimes results in an enhanced surface finish.
Deep Draw Efficiency: Streamlining Production
The Deep drawing process also typically eliminates the need for secondary forming operations, as the final geometry can be achieved with one or two strokes of the press. The process can be fully or partially automated by setting the press parameters for precise and accurate control. With high repeatability and consistency, producing high-volume or low quantities will meet exact requirements and specifications while minimizing defects like wrinkling and tearing. The efficiency of the process reduces material waste and scrap, contributing to cost-savings and supporting sustainability initiatives.
Because of their seamless build, many deep drawn parts can be used nearly immediately after forming. Components often require no welding or further forming, allowing them to be cleaned, inspected, and shipped. Overall, deep draw metal stamping simplifies assembly and accelerates throughput, an excellent process for a multitude of applications.
Capacity: Small or Large Production Runs
With the use of automated and semi-automated presses, deep draw operations can be performed continuously, streamlining production and improving cycle efficiency. Parameters can be set on the press to draw the exact same shape, for large or small production runs. Â Depending on the part geometry, some applications can be formed from a single metal blank in one stroke of the press, while others may need a couple re-draws. This efficiency reduces the need for additional fabrication or secondary metal forming operations, minimizing production time and shortening lead times.