Rectangular sheet metal deep drawing is where sheet metal parts with rectangular cross section and shape are fabricated using deep drawing technique. Deep drawing technique is where a sheet of metal is pressed by a plunger into a die. Due to this, the sheet takes the exact shape of the die.
Rectangular sheet metal deep drawing produces seamless parts with excellent dimensional accuracy and quality. Process produces parts with a rectangular cross section but can have any geometric features that a deep drawing process can deliver.
A rectangular sheet metal deep drawing process can be done in a few simple steps. First step involves cutting the sheet into the right size through the process of sheet metal cutting. It is important to consider the final product shape and material properties to cut the sheet into required size. Any mistake in initial cutting of the sheet can affect the entire further process.
Second step involves the deep drawing of the sheet metal into the required rectangular product. To do the deep draw, sheet metal is placed and clamped onto the surface of the die. Then a plunger is used to gradually force the sheet into a rectangular shape die. The die and plunger both have the cross section and shape according to the cross section and shape of the required product.
Third step is getting the final shape of the product. Deep drawing processes the near net shape products. Near net shape, means the product has a shape near to the final shape required. In deep drawing, usually the main shape of the product is achieved and after that small process like removing edges, punching holes and making cuts is done .
Final step in the deep drawing process is always the surface finish. Deep drawing produces smooth surface finish on the deeply drawn part of the product but not on edges. Edges need to be cut and processed to produce required surface finish.
Other than this some rectangular deep drawn parts need special surface coating to achieve special properties like corrosion resistance, wear resistance or just need paint to enhance aesthetics.
Rectangular deep drawing process is highly affected by materials properties. What shape or dimensions can be achieved using deep drawing depends on the material properties of sheet metal.
Material properties that influence the rectangular deep drawing process are as follows.
Plasticity
Plasticity refers to a material property that enables the metal sheet to deform during deep drawing without getting fractured. Higher the plasticity of a material, the better it is for deep drawing. Higher plasticity means the material can take the most difficult shapes.
Elongation
Elongation refers to a material property that enables the metal sheet to have an increase in length of sheet with decrease in diameter or thickness. Higher the elongation percentage of a material better it is for deep drawing. Higher elongation percentage means that material can be processed for a deeper draw.
Yield Point
Yield point refers to a point in material stress strain graph where its elastic deformation ends and plastic deformation starts. Lower yield point means material will start plastic deformation earlier without the requirement of much external stress.
Strength
Material strength refers to a material property that enables material to resist external load without fracture. Higher the value of material strength, better it is for deep drawing application. High strength makes sure that the sheet can take the high stress developed during deep drawing.
There are several factors that affect the costing of a rectangular deep drawing process. Following is a complete explanation of these factors that affect the cost of the deep drawing process.
Tooling cost
Tooling refers to the die and punch/plunger design developed for the specific product of deep drawing. It is usually the highest single item cost associated with the process. This tooling also adds lead time to the process. Lead times can be from days to weeks depending on the size of the product.
Size of the die and plunger also impact the cost associated with the process. The tooling cost is not a one time cost. Die and plunger might need to be replaced when critical features replica made on die get worn out with time.
Material cost
It's the most obvious cost associated with the process. The material cost not only considers the cost of the sheet used in the deep drawing process but also considers the material wasted when cutting the sheet to actual size needed for deep drawing.
Process cost
Process cost involves the cost of operating the machine and any other material or tools that might be needed to operate the machine. This is a continuous cost and can be reduced by optimizing the process.
Post process cost
As deep drawn products need post processing to develop final shape. So post process cost is also a major cost associated with the product. It depends on the number of post processes required to achieve the final shape. Post processes may or may not have their own tooling cost, and material cost.
Labor Cost
As processes need skilled labor to perform deep drawing and processes might need more than one labor to complete the process. Labor cost is also a continuous cost, and it highly influenced the product cost.
Material and industry | Electronics Industry Product | Mechanical Industry Product | Medical Industry Product |
Stainless Steel | Smartphone Frames | Metal Brackets | Medical Instrument Trays |
Aluminum | Laptop Chassis | Metal Boxes | Medical Equipment Housings |
Copper | Rectangular Electrical Enclosures | Copper Panels | Rectangular X-ray Detector Housings |
Brass | Electrical Outlet Boxes | Brass Plates | Dental Equipment Casings |
Titanium | Aerospace Control Panels | Rectangular Titanium Blocks | Surgical Tray Components |
Nickel Alloys | Rectangular Sensor Housings | Industrial Equipment Panels | Rectangular Pacemaker Cases |
JCL being a leading firm in deep drawing process offers some great advantages to its client that no other workshop can offer.
JCL has all the latest technology and techniques related to deep drawing.
JCL offers high quality products though standardize quality control.
JCL has the best and highly skilled workforce that is fully capable of processing any product through a deep drawing process.
JCL offers the best value of your time and money. We make sure your product meets international standards and passes all quality tests.
We are excited to collaborate with you!
If you have any questions about our products or require custom machining services, please don’t hesitate to reach out to us. We are here to assist you and provide the solutions you need.
