Sheet Metal Forming Processes

Deep Drawing
Like shearing but with clearance > material thickness The Process
Place round blank over die Clamp in place Punch travels downward into die
metal deforms by stretching into the die

Deep Drawing

Deep Drawing
Advantages
Very high production rates (e.g. cans) Can make parts no other process can make
Containers of all shapes and sizes

Deep Drawing
c = Clearance Db = blank diameter Dp = Punch diameter Rd = die corner radius Rp = Punch corner radius F = drawing force Fh = holding force

Disadvantages
Limited shapes Material quality critical to obtaining good parts Dies are expensive

Deep Drawing

Blankholder force

Deep Drawing Parameters and Practices

Too high - workpiece tears Too low - - cup gets wrinkles Blankholder force is 0.7 to 1 % of the total of the yield and ultimate tensile strength of the workpiece

Initial step

bending of edge

straightening of side wall

Radius/diameter of punch Diameter of blank Thickness of blank

Thinning and drawing

final cup shape

Deep Drawing Parameters and Practices

Clearance between punch and die
Clearances usually 1.07 to 1.14 thickness Too low - blank pierced

Deep Drawing Forces and Stresses

Stress states are complex, force difficult to compute
Under blankholder
Compressive through thickness Tensile along radius Compressive (poisson's effect along circumference

Friction/lubrication Radius of entry into die Radius on end of punch

too small - cracking at corners Too large - wrinkling

In die
Mostly tensile in punch direction Also tensile at right angles to punch direction Stresses cause material to thin in punch direction and shrink around die in circumferential direction

Punch force

Deep Drawability
Deep drawability is a complex phenomenon An important empirical metric is
Limiting Drawing Ratio (LDR) given by
LDR = Maximum blank diameter Punch diameter

Normal Anisotropy
Normal Anisotropy,
R = width strain/thickness strain LDR is proportional to the average normal anisotropy

LDR is related to fundamental properties of the material being drawn through a mechanical property called:
Normal or Plastic Anisotropy

It is measured by measuring the deformations in length on width of a normal tensile specimen

LDR and Anisotropy

Deep draw cup with ears

Metal Flow
Between die and punch flow is similar to that in drawing Under the blankholder much smaller metal movement and is uniform In non-circular products flow becomes nonuniform To control flow in non--circular products use
Drawbeads
The bending and straightening of the metal as it flows provides greater resistance to metal movement Design and location important to good products

Metal Flow

Design blank appropriately

Cut corners of square blanks at 45o

Drawing Defects

Sheet Metal Forming Processes

Ironing & Redrawing

a) Wrinkling in flange - small holding force b) Wrinkling in the wall - insufficient holding force, wrinkling initially occurring on the flange. c) Tearing - high stress, sharp die radius d) Earing - anisotropy of the material e) Surface scratches - Die or punch not having a smooth surface, insufficient lubrication

Ironing
Reduces thickness variation from top to bottom of cup Like drawing a sheet where the die is formed by the clearance between the punch and its die

Redrawing
Used for complex shapes Multistep dies Reverse redrawing Allows very deep cups to be formed (Beverage cans)

Redrawing

Reverse Redrawing

Deep Drawing of Cans

7 Sheet metal operations

Deep Drawing of Cans

2 - Deep Drawing

1 - Blanking

3 - Redrawing

Deep Drawing of Cans

Deep Drawing of Cans

4 - Ironing

6 - Necking

5 - Doming

7 - Seaming

Sheet Metal Forming Processes

Stretch Forming
Used predominantly to make aircraft parts Like stretch bending for tubes, but uses flat sheet Material is pulled across a tool while being subjected to tensile stress

Stretch forming

Stretch Forming

Stretch forming

Advantages
Suitable for low volume production Versatile Economical, inexpensive dies

Disadvantages
Cannot form parts with sharp corners or depressions

Other Related Processes

Rubber forming
Large flexible rubber base acts as a die
The rubber acts like a semi fluid medium pushing the sheet against the die shape

Rubber Forming

Advantages
Only one side of the die needs to be made

Disadvantages
Shapes are limited

Other Related Processes

Hydroforming or fluid forming
Uses a fluid medium separated from the workpiece by a rubber membrane Fluid kept under high pressure (100 MPA, 15,000 psi) during the forming cycle

Other Related Processes

Spinning
Similar to forming pots with clay on a potters wheel Only for axisymmetric parts Usually involves multiple passes May require elevated temperatures for thick parts or low ductility materials

Types of Spinning
Conventional
thickness retained, outside diameter typically reduced

Conventional Spinning

Shear spinning/power spinning/flow turning/ hydrospinning/spin forging

Thickness reduced, outside diameter retained

Shear spinning
Also known as power spinning, flow turning, spin forging Related to Ironing

Types of Spinning
Tube Spinning
Wall thickness reduced Can be executed
internally or externally forward or backward

Used to make
Pressure vessels Car and truck wheels Rocket and missile parts

Other Related Processes

Shock Wave Forming
Shock created by
Explosives (Explosive Forming) Electric spark ( Electrohydraulic forming) Gas

Other Related Processes

Magnetic pulse forming
Pulsed magnetic forces move the metal against a die Often used to seal a tube against a cylindrical part

Uses a hydrostatic shock wave to push material into a die. Still need to clamp the workpiece to the die

Forming Equipment
Like forging presses Important parameters for forming equipment
Stiffness Rigidity

Forming Equipment
Selection parameters include:
Type of forming Size and shape of the workpiece Length of stroke of the slides Number of strokes per minute Speed and shut height Number of slides Maximum force Type of controls Die change mechanism

Several types
Mechanical Hydraulic Pneumatic Pneumatic/hydraulic

Forming Equipment Shapes

C-Frame most common
Easy access

A Large Stamping Press

O or box- type stiffer Can have several presses linked by automated transfer equipment

Break Press

Die Design

Die Design
Summary Die set components Types of die sets Strippers Knockouts Shedders Compound dies Progressive dies

Die Design
Introduction Die sets are tools to hold and aid in the alignment of..
cutting forming bending etc.

Die Design
Introduction

Die Design
Introduction Guide bushings and guide pins
align the punch and die holders

Shank
fits into the press ram

Flange
to fix the die holder to the press

Die Design
Introduction Stamping tools are mounted between the punch and die holders. Accurate slip fit is maintained between the guide pins and the guide bushings. Precision die sets
ball bearing bushing are used

Die Design
Die Sets Selection
feeding method rigidity required viewing access alignment accuracy

Die Design
Die Sets

Die Design
Die Sets

Die Design
Strippers Applies pressure to the stock strip sticking occurs Designed to..

Die Design
Punches
not to deflect withstand stripping forces not to rotate with cutting action

life extended by heat treatment

strength wear resistance

Die Design
Punches Punch deflection avoided by making the body diameter of the punch larger than the cutting edge.

Die Design
Punches

Die Design
Piercing Punches Smaller and longer than blanking punches Designed to withstand shock, deflection, and buckling Higher likelihood of damage
easy removal/ replacement

Die Design
Punches Smaller diameter punches need support for most of their length

Die Design
Punches Thin short punches - a quill provides support

Die Design
Punches Thin punches a quill provides support

Die Design
Punches To prevent the punch from turning in the punch plates.

Die Design
Die Blocks

Die Design
Die Blocks Sectioned blocks
large die blocks difficult machining intricate shapes

Die Design
Compound dies Combine one or more operations in one station during one stroke of the press.

Die Design
Compound dies Advantages
Pierced holes are held to close tolerances and concentricity with edges. Larger parts can be blanked in a small press Compound dies are economical
one press one operator

Die Design
Compound dies Advantages
Besides cost savings relocation errors can be minimized. Elimination of inaccuracy

Die Design
Compound dies Disadvantages
Certain parts or blank shapes and sizes, compound dies are not suitable. Too much die detail crowded into one area,

Die Design
Compound Dies Multiple operations within same stroke

Example,
Punched hole too close to the edge of the blank => failure

Die Design
Progressive Dies Made with two or more stations in a row. As the press ram descends
each station performs an operation on the workpiece idler station

Die Design
Progressive Dies The part remains attached to the scrap skeleton until the last station.
Cut-off

Each press ram stroke

complete workpiece

Stock strip advances

series of stations one or more die operation

Scrap skeleton
cut-up by a scrap cutter

Die Design
Progressive Dies : Operations
Several stamping operations are combined and performed in successive stations.

Die Design
Progressive Dies Other names
Cut & carry die Follow die Gang die

Operations which may be included in a progressive die:

Piercing, blanking, forming, drawing, and cutoff

Die Design
Progressive Dies : Pilots Parts must be fed and located accurately in a progressive die. Stock positioning Direct pilots
holes punched in the part

Die Design
Progressive Dies : Pilots Advantages
Not affected by workpiece change Size and location not limited (as with direct pilots)

Disadvantages
Material width and lead may increase Drawing affects scrap-strip

Indirect pilots
holes pierced in scrap-strip.

Die Design
Progressive Dies : Stations Distance from one station to the next must be the same. Station-to-station distance = The distance the strip moves to relocate at each station Die cost
high

Die Design
Progressive Dies : Costs

Production runs
high volume

Press cost
high : automatic press with cut-off, feed, straightener etc.

Die Design
Progressive Dies Operator requirement
reduced : main task is to replace the coil of stock.

Die Design
Progressive Dies

Scrap
high : nesting is limited

Die Design
Progressive Dies

Die Design
Progressive Dies

Die Design
Progressive Dies

Die Design
Progressive Dies

Die Design
Simple Die : Trimming