Deep Draw Tooling Design

Deep draw tooling includes all the hard tooling components used to shape flat sheet metal into a deep-drawn part:

• Dies
• Punches
• Blank holders
• Knockout cylinders

Dies and punches are made of tool steel, while blank holders and knockout cylinders are typically made of alloy steel. The rims of the punch and drawing ring are rounded so the sheet metal blank forms smoothly over the die’s edge.

Hydraulic and mechanical deep-drawing presses are used to produce deep drawn stampings. Deep draw presses have customizable configurations to accommodate different tooling requirements, and can have single or multiple stations.

ATACO can provide deep drawing along with secondary operations such as trimming, piercing, and forming. If volume is too low to justify tooling for these additional operations, we can trim and pierce via 5-axis laser cutting.

The punch is positioned on the press bed with the die directly above it. The blank holder (a plate with an opening for the punch) holds the edges of the blank against the die to help control material flow into the die’s cavity. This helps minimize defects in the finished part.

As the upper die presses the blank down, the metal material is formed over the punch. During drawing, a cushioned pressure pad keeps the blank in contact with the end of the punch to reduce tensile stress, which could cause tearing.

After the workpiece has been formed, the knockout cylinder ejects the part using just enough force to free it from the die cavity without causing damage.

Designing deep draw tooling requires metal forming expertise. There are many different factors to consider which can affect part quality, lead time and final cost.

Depth of draw and draw ratio determine the shape of the punch and die cavity, as well as the diameter of the metal blank.

Part complexity determines the number of stations needed. The toolmaker also has to incorporate elements that move the workpiece from one station to the next.

Production volume and drawing force determine which material is used for the punch and die.

Workpiece material knowledge is crucial for successful tooling design. Material type, grade, heat treating, and anisotropy (directional properties) affect flow and therefore tooling requirements. Softer materials are easier to draw and require less force. Some metals have more springback than others. The desired thickness of the blank and finished part also affect tool design.

ATACO toolmakers take these and many other considerations into account when designing tooling for deep drawn components.

ATACO uses state-of-the-art production simulation software for deep drawing die design. FASTFORM® Advanced allows our engineers to quickly assess deep drawn part feasibility, blank shape and springback, as well as identify potential forming issues. Simulation data on formability risks and optimal material usage is then sent to our tooling department.

ATACO toolmakers use the software in the deep drawing die design phase to evaluate component and tool geometry, incorporate material properties, and account for predicted production effects resulting from friction, blank holder force, pad pressure and more.

The design process includes many factors that affect the final cost. Using specialized software to optimize die design and cost-effectiveness increases ROI for our high-volume manufacturing clients.

Deep draw stamping is one of the most cost-effective manufacturing processes because the cost per part decreases as production volume increases. ATACO is committed to delivering cost-efficient parts with consistent quality by using the most advanced technologies and equipment.

Learn more about our deep draw stamping capabilities or request a quote for your project.