Deep Drawing

Description

Deep drawing is a sheet metal forming process used industrially to produce cup-shaped, box-shaped, and other complex-curved hollow-shaped sheet parts. The process creates deep, seamless and round shapes from sheet metal. During deep drawing, a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. It is thus a shape transformation process with material retention. The process is considered "deep" drawing when the depth of the drawn part exceeds its diameter. 

There are 4 steps for deep drawing process:

-Cutting Blanks

The deep drawing process starts from a flat disc that blanked from a steel sheet. Auwell improves material utilization by staggering our blanks to reduce scrap and material costs. The deep drawing process minimizes waste, optimizing the efficiency of material usage.

-Starting Cup

After cutting the blank at the first die station, the blank is cupped around the nose of a punch and pressed into a die to form a cup. This first deep drawing forming operation increases the strength of the part through work hardening.

-Keep Drawing

Depending on your desired length-to-diameter ratio, Auwell will design dies with several draws to create the basic shape of your deep drawing parts. The forces produced in the deep drawing process naturally cause the shell wall to thin out, while the shell flange thickens at each stage. Our professional team designs the die to stretch the metal as evenly as possible into the part’s desired shape.

-Post-Drawing Process

After obtaining the desired shape of the product, the following process can be assembled to other components or as semi-finished products for future processes including deburring and surface treatment including polishing, zinc-plating, nickel plating, chormating, powder coating, painting, etc.

The Benefits of Deep Drawing process

-Speed

It’s usually the most efficient method for orders of large quantities 

-Eliminates assembly steps.

Deep drawing produces shapes with closed ends. This avoids the need to cut and weld multiple pieces. 

-Seamless

A deep drawing can or tube shape has no joins. This makes deep drawing an ideal process for anything that needs to be water or air-tight.

-High accuracy

Parts coming off a forming press are extremely repeatable. If the die was made correctly, they’ll also conform very closely to the drawing.

-Produces complex geometries.

Deep drawing can produce complex parts like an oil pan for an engine or complex filter housings.

-Produces very strong parts

Many metals work-harden as they deform. Essentially, their crystal structure allows a certain amount of movement but beyond that, it becomes locked. Deep drawing subjects metal to a lot of deformation, resulting in tough finished parts with high strength.

Auwell is capable of designing and developing necessary tooling for deep drawing production. CMM is available for sample dimensional inspection. Surface treatment includes KTL, powder coating, painting, zinc plating. PPAP documents are available upon request.

Technical Specifications

-Materials

Mild steel, stainless steel, copper, brass, aluminum, and alloy steel. 

-Machine capacity

1,200-ton hydraulic press machine, 800-ton stamping machine.

Thickness ranged from 0.2mm to 6mm.

  

Advantages

Our deep drawing parts offer numerous advantages over traditionally machined, cast, or molded parts. We can reverse-engineer existing components, and can often combine multiple parts into a single stamped piece. The advantages of deep drawing process are:

-Reduce costs

-Reduce waste

-Lower assembly cost and time

-Improve metal structure to produce stronger finished parts.

Besides the technical advantages of deep drawing process, the competitive advantages of working with Auwell are:

-Rich Experience

More than 20 years of experience in deep drawing products development and production, especially to the European and North American markets, with solid understanding of the material, technical and quality standards worldwide.

-Fast Turnaround

Generally, we provide a quotation within 3 working days. Combining the latest manufacturing technologies and facilities, Auwell can provide fast prototypes in just 2 weeks for simple projects.

-Comprehensive Solution Provider

Auwell provides comprehensive services for deep drawing projects starting from designing, through prototyping, tooling/fixture development, sampling, mass production, and to logistic and post-sale support.

-Rigid QC Policies

The most rigorous quality policy starts from material control, and is followed through to final pre-shipment inspection. Material certificates include the mill certificate, 3rd party chemical components, and mechanical property reports, as well as RoHS and REACH reports upon request. Other reports include dimensional reports, surface treatment thickness, and salt fog test reports, etc. We structure our processes, creating Flow Charts and Control Plans before production, making sure all QC processes are in accordance with ISO9001-2015 requirements and drawing specifications.

-Flexible Payment Term

Tooling payments need to be pre-paid. For mass production, we offer flexible payment terms, reasonable credit terms will be given, the client only pays when they are happy with the product they received. For long-term projects, we offer call-off inventory services for fast delivery requirements.

Applications

Sheet metal fabrication products have widely been used in almost all industrial sectors including: 

-Aerospace and defense

-Automotive

-Energy

-Electronics

-Construction

-Transportation

-Industrial

-Consumer Products

The following catalogues of deep drawing products are the ones which Auwell has produced and supplied to our distinguished worldwide clients. Click following pictures for details. Please be advised, most of the products are for demonstration purpose only. 

Deep Drawing & Spinning

Elevator Door Pulley