The Process of Forming Deep-Drawn Metal Stamped Aluminum Parts

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.