Aluminum is a very formable material, making it the perfect candidate to be deep drawn, stamped, or hydroformed. The deep draw metal stamping processes is a cold-forming process, meaning the material’s grain structure undergoes changes at room temperature, as the blank forms and stretches into its final shape, while simultaneously boosting its strength capabilities. As a benefit of deep draw sheet forming, the hardening of aluminum’s material properties makes it stronger and more durable as it is formed. Aluminum seamlessly formed pieces are very popular among manufacturing industries because of their strength, ductility, longevity, and great reputation.
Aluminum is a highly versatile metal that can be formed through a variety of manufacturing processes to serve a multitude of industries including food processing, aerospace, defense, medical, marine applications, and more. Why is Aluminum such a popular material choice? Because of its mechanical and physical properties:
With it’s impressive strength-to-weight ratio, it is only one-third of the weight of steel, yet is equally as strong. Because of this, aluminum is a very attractive option for aerospace, defense and other applications where high strength and low weight is key.
Though aluminum is light in weight, it can be formed into durable and long-lasting shapes. Because deep draw forming is a cold-working process, the grain structure of aluminum undergoes changes while it forms and stretches into its final shape, increasing its strength capabilities. The draw forming process allows the material to harden throughout being formed, making it stronger and more durable throughout the process. Common alloys are 6061 and 6063, both known for their excellent strength. Being such a lightweight metal with such durability makes Aluminum a top choice for a variety of industries.
Though aluminum has different properties than steel and other metals, and forms differently, it is still a great option for deep draw metal stamping. It is a great material to utilize in both low or high-volume production runs.
Aluminum is 100% recyclable, allowing it to be reprocessed and formed into new applications an infinite amount of times. It is one of the most sustainable metals available. This assists in sustainability efforts, while minimizing scrap and waste.
Aluminum behaves differently than stainless steel and other metals during the deep draw process, due to its inelastic properties. Unlike stainless steel, which can flow and redistribute its thickness under force, aluminum cannot be overstretched or excessively deformed. While aluminum can be deep drawn, it requires a more specific and controlled approach to prevent tearing or wrinkling.
The begin, the sheet metal blank must be placed properly on the press, where it is close enough to the punch to be forced into the cavity, allowing for the proper flow of metal. If the blank is placed too far or slightly off, the material will stretch, resulting in a fracture or break. The compression will result in an inward motion of the material. In other words, the metal being displaced will come out as nearly the same surface area as the initial blank. Most materials will typically resist metal flow when compressed, proving the correct amount of material and force is absolutely accurate.
A successful aluminum draw depends on maintaining the correct draw ratio: the relationship between the punch diameter and the metal blank diameter. Because aluminum strains locally with limited elongation, it lacks the stretch distribution that stainless steel offers. To ensure quality results, the press parameters must be set to balance stretching, compression, and the blank holder force appropriately. The success of the draw is also dependent on proper lubrication that responds well with aluminum. Each material requires different lubricants for different reasons, depending on their properties. With the appropriate lubrication and these parameters properly controlled, a clean and precise aluminum draw with no defects or errors can certainly be achieved.
Typical aluminum applications:Â
Aluminum is very durable, yet lighter in weight compared to other metals. Because of this, you can find aluminum at the center of many structural supports. Markets that aluminum is heavily utilized in include: aerospace, automotive, architecture, packaging, construction, railroad transportation, marine transportation, electrical appliances, medical devices/equipment, electronics, machinery, and consumer goods.
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.
Benefits of Forming Deep Drawn Metal Stamped Parts The deep drawing sheet metal forming process is a cold-forming process performed in an environment at or near room temperature, where the metal is permanently deformed into the desired geometry. In this process, the flat metal blank is formed and stretched around a die cavity with a
What is the Trimming Process and How is it Performed? Trimming is a process used to remove excess material to achieve a desired shape, size, and finish, while removing burrs and smooths out sharp edges. To trim a part, it is put on a lathe and processed by a highly skilled metal spinner, or a
The Metal Finishing and Polishing Process The polishing process is a secondary metal fabrication process that is done to create a smooth and shiny surface by utilizing abrasives or chemical treatment, and can be done by hand or robotic automation. The purpose of adding a finish or polish is to improve the appearance by creating
The Benefits of One-piece Constructions At Toledo Metal Spnning Company, we have been forming metals since 1929. With nearly a century of experience, we have mastered a wide range of processes including laser cutting, metal spinning, deep drawing, machining, rolling and seam welding, to build strong and durable high-performance parts. But what truly sets us
The History of Deep Draw Metal Stamping What is Deep Drawing? Deep Draw forming with conventional tool and die technology is the conforming of sheet metal, commonly referred to as a blank, around a plug in either a hydraulic or mechanical press. The edges of the blank are restrained yet allowed to slide by a precise
What is Hydroforming? Hydroforming, or utilizing the hydro-mechanical-press is a metal forming process where complex and structurally sound parts with tight tolerances that can be made from various metals. A water-based fluid force, oil, gas, or a flexible elastic polymer membrane, is highly pressurized up to 10,000 PSi is applied onto a piece of metal,
Clarifying Elements to the Deep Draw Design Process – The Draw Ratio When it comes to tool design, the most important formula is The Draw Ratio, also known as Limiting Draw Ratio (LDR). The formula is: LDR = D / d D = blank diameter d = cup ID or punch diameter This ratio shows
What are the differences of Deep Drawing and Hydroforming? Hydroforming is a specialized Deep Drawing process also known as Sheet Hydroforming. Sheet hydroforming allows various materials to become complex and structurally sound parts. It allows for asymmetrical or irregular shaped geometries, while conventional Deep Drawn parts are symmetrical and uniform throughout the entire shape. Another
