Manufacturing Processes for Engineering Materials, 5th ed.

Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Sheet-Metal Forming Processes
TABLE 7.1 General characteristics of sheet-metal forming processes.
Process Characteristics
Roll forming Long parts with constant complex cross-sections; good surface nish; high
production rates; high tooling costs.
Stretch form-
ing
Large parts with shallow contours; suitable for low-quantity production; high
labor costs; tooling and equipment costs depend on part size.
Drawing Shallow or deep parts with relatively simple shapes; high production rates;
high tooling and equipment costs.
Stamping Includes a variety of operations, such as punching, blanking, embossing,
bending, anging, and coining; simple or complex shapes formed at high
production rates; tooling and equipment costs can be high, but labor costs
are low.
Rubber-pad
forming
Drawing and embossing of simple or complex shapes; sheet surface protected
by rubber membranes; exibility of operation; low tooling costs.
Spinning Small or large axisymmetric parts; good surface nish; low tooling costs, but
labor costs can be high unless operations are automated.
Superplastic
forming
Complex shapes, ne detail, and close tolerances; forming times are long,
and hence production rates are low; parts not suitable for high-temperature
use.
Peen forming Shallow contours on large sheets; exibility of operation; equipment costs
can be high; process is also used for straightening parts.
Explosive
forming
Very large sheets with relatively complex shapes, although usually axisym-
metric; low tooling costs, but high labor costs; suitable for low-quantity
production; long cycle times.
Magnetic-pulse
forming
Shallow forming, bulging, and embossing operations on relatively low-
strength sheets; most suitable for tubular shapes; high production rates;
requires special tooling.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Localized Necking

2
(a) (b) (c)

2
=
3
/2

1
2~110
Diffuse neck Localized neck
(d)
FIGURE 7.1 (a) Localized necking in a sheet-metal specimen under tension. (b) Determination of the
angle of neck from the Mohr's circle for strain. (c) Schematic illustrations for diffuse and localized
necking, respectively. (d) Localized necking in an aluminum strip in tension; note the double neck.
Source: S. Kalpakjian.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Lueders Bands
(a)
Yield-point
elongation
Yielded metal
Lueder!s band
Unyielded metal
0
Strain
S
t
r
e
s
s
Y
upper
Y
lower
(b) (c)
FIGURE 7.2 (a) Yield-point elongation and Lueders bands in tensile testing. (b) Lueder's bands in annealed
low-carbon steel sheet. (c) Stretcher strains at the bottom of a steel can for common household products.
Source: (b) Courtesy of Caterpillar Inc.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Stress-Corrosion Cracking
FIGURE 7.3 Stress-corrosion cracking in a deep-drawn brass part for a
light xture. The cracks have developed over a period of time. Brass and
300-series austenitic stainless steels are particularly susceptible to stress-
corrosion cracking.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Shearing Process
Punch
Die
Sheet
A
B D
C
c
T
F
Punch
Slug
Sheet
Die
Penetration
Fracture
surface
Clearance
FIGURE 7.4 Schematic illustration of the shearing process with a punch and die, indicating important process variables.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Hole & Slug
(a)
Rollover depth
Penetration depth
Burnish depth
Fracture
angle
Burr height
F
r
a
c
t
u
r
e
d
e
p
t
h
Breakout
dimension
Sheet
thickness
Burnish
dimension
Flattened portion
under the punch
Burr height
Dishing
Burr
Rough surface
Smooth surface
(burnished)
Ideal slug
A
C
B D
(b)
FIGURE 7.5 Characteristic features of (a)
a punched hole and (b) the punched slug.
Note that the slug has a different scale
than the hole.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Shearing Mechanics
(a) (b)
1. 2. 3.
Punch
Clearance, c
Die
1
2
0

1
2
0

1
4
0

(
H
V
)

1
4
0

1
6
0

1
8
0

2
0
0

1
6
0

2
0
0

2
2
0

1
8
0

1
4
0

1
4
0

1
8
0

1
6
0

2
0
0

1
2
0

1
2
0

1
6
0

1
8
0

2
0
0

FIGURE 7.6 a) Effect of clearance, c, on the deformation zone in shearing. Note
that, as clearance increases, the material tends to be pulled into the die, rather
than being sheared. (b) Microhardness (HV) contours for a 6.4-mm (0.25-in.)
thick AISI 1020 hot-rolled steel in the sheared region. Source: After H.P. Weaver
and K.J. Weinmann.
F
o
r
c
e
Penetration
0
FIGURE 7.7 Typical punch force vs.
penetration curve in shearing. The
area under the curve is the work
done in shearing. The shape of the
curve depends on processing
parameters and material properties.
Maximum punch force:
F
max
=0.7(UTS)tL
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Shearing Operations
(a) (b)
Discarded
Punching Blanking
Parting
Lancing
Perforating
Notching
Slitting
FIGURE 7.8 (a) Punching and blanking. (b) Examples of shearing operations on sheet metal.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Fine Blanking
(b)
(a)
Upper pressure pad
Blanking punch
Stinger (impingement ring)
Sheet metal
Punch
Slug
Sheet
Die
Upper
pressure
pad
Clearance
Fracture
surface
Lower
pressure
cushion
Blanking die
Lower pressure cushion
Support
FIGURE 7.9 (a) Comparison of sheared edges by conventional (left) and ne-blanking
(right) techniques. (b) Schematic illustration of a setup for ne blanking. Source: Feintool
International Holding.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Rotary Shearing
FIGURE 7.10 Slitting with rotary blades, a process similar to opening cans.
Driven
cutter
Clearance
Ilding
cutter
Workpiece
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Shaving & Beveled Tooling
FIGURE 7.11 Schematic illustration of shaving on a sheared edge.
(a) Shaving a sheared edge. (b) Shearing and shaving combined in
one punch stroke.
(a) (b)
Sheared
edge
Sheet
Die
Sheet
Die
Clearance
FIGURE 7.12 Examples of the use of shear angles on punches and dies.
Compare these designs with that for a common paper punch.
(a) (b) (c) (d)
Double-bevel shear Convex shear
Blank
thickness
Shear angle
Punch
Die
Bevel shear
Punch
Die
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Progressive Die
FIGURE 7.13 (a) Schematic illustration of producing a washer in a progressive die. (b) Forming of the top
piece of a common aerosol spray can in a progressive die. Note that the part is attached to the strip until
the last operation is completed.
(b) (a)
Ram
Blanking
punch
Pilot
Scrap
Die
Stop
Finished
washer
Strip
Scrap
Strip
Stripper
Piercing
punch
First
operation
Slug
Part
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Tailor-Welded
Blanks
FIGURE 7.14 Examples of laser-welded and
stamped automotive body components.
Source: After M. Geiger and T. Nakagawa.
(a)
(b)
Blanking;
laser cutting
Laser welding Stamping
g 60/60 (45/45)
m 20/20
Legend
Hot-galvanized alloy steel sheet. Zinc amount: 60/60 (45/45) g/m
2
.
Double-layered iron-zinc alloy electroplated steel sheet. Zinc amount 20/20 g/m
2
.
1 mm
1 mm
m 20/20
0.8 mm
g 45/45
g 60/60
1 mm
g 45/45
1 mm
g 45/45
0.7 mm
1.5 mm
0.7 mm
1.25 mm
Floor plate
2.0 mm
0.8 mm
Motor-compartment
side rail
0.7 mm
0.7 mm
1.5 mm
Quarter inner with integrated
shock-absorber support
Fender with
integrated reinforcement
Girder
1.5 mm
2.0 mm
Shock-absorber
support
1.5 mm
2.5 mm
1.5 mm 0.7 mm 0.7 mm
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Bending & Minim Bend Radius
FIGURE 7.5 (a) Bending terminology.
Note that the bend radius is measured to
the inner surface of the bend, and that the
length of the bend is the width of the
sheet. (b) Relationship between the ratio
of bend-radius to sheet-thickness and
tensile reduction of area for a variety of
materials. Note that sheet metal with a
reduction of area of about 50% can be
bent and attened over itself without
cracking, similar to folding paper. Source:
After J. Datsko and C.T. Yang.
20
15
10
5
0
0 10 20 30 40 50 60 70
Tensile reduction of area (%)
R
t
= (60/ r ) - 1
B
e
n
d

r
a
d
i
u
s

(
R
)
T
h
i
c
k
n
e
s
s

(
t
)
(a) (b)
T
Length of
bend, L
Bend
allowance, L
b
Bend
angle,
Bend radius, R

Bevel angle
Setback
Material Condition
Material Soft Hard
Aluminum alloys 0 6t
Beryllium copper 0 4t
Brass, low leaded 0 2t
Magnesium 5t 13t
Steels
austenitic stainless 0.5t 6t
low carbon, low alloy, and HSLA 0.5t 4t
Titanium 0.7t 3t
Titanium alloys 2.6t 4t
TABLE 7.2 Minimum bend radii for
various materials at room temperature.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Bending Mechanics
FIGURE 7.16 The effect of length of bend
and edge condition on the ratio of bend
radius to thickness for 7075-T aluminum
sheet. Source: After G. Sachs and G. Espey.
4
3
2
1
0
B
e
n
d

r
a
d
i
u
s
T
h
i
c
k
n
e
s
s
1 2 4 8 16
Length of bend
Thickness
Plane
stress
Plane
strain
Rough
edge
Smooth
edge
FIGURE 7.17 (a) and (b) The effect of elongated inclusions (stringers) on
cracking in sheets as a function of the direction of bending with respect to
the original rolling direction. This example shows the importance of
orienting parts cut from sheet to maximize bendability. (c) Cracks on the
outer radius of an aluminum strip bent to an angle of 90; compare this
part with that shown in (a).
(c) (a) (b)
Rolling
direction
Cracks No cracks
Elongated
inclusions
(stringers)
Rolling
direction
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Springback
FIGURE 7.19 Springback factor, Ks, for
various materials: (a) 2024-0 and 7075-0
aluminum; (b) austenitic stainless steels;
(c) 2024-T aluminum; (d) 1/4-hard
austenitic stainless steels; and (e) 1/2-
hard to full-hard austenitic stainless
steels. A factor of Ks =1 indicates that
there is no springback. Source: After G.
Sachs.
R
f
R
i After
Before
T

f
FIGURE 7.18 Terminology for springback
in bending. Note that the bend angle has
become smaller. There are situations
whereby the angle becomes larger, called
negative springback (see Fig. 7.20).
1.0
0.9
0.8
0.7
0.6
0.5
S
p
r
i
n
g
b
a
c
k

f
a
c
t
o
r

(
K
s
)
a
b
c
d
e
1 5 10 20
R/T
No springback
Increasing springback
Springback factor:
Springback estimation:
K
s
=
!
f
!
i
=
(2R
i
/t) +1
(2R
f
/t) +1
R
i
R
f
=4

R
i
Y
Et

3
3

R
i
Y
Et

+1
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Negative Springback
FIGURE 7.20 Schematic illustration of the stages in bending round wire in a V-
die. This type of bending can lead to negative springback, which does not
occur in air bending (shown in Fig. 7.24a). Source: After K.S. Turke and S.
Kalpakjian.
Punch
Die
Wire specimen
(a) (b) (c) (d)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Springback Compensation
FIGURE 7.21 Methods of reducing or eliminating springback in bending operations.
Source: After V. Cupka, T. Nakagawa, and H. Tyamoto.
W
b
, 90 , 90 90
90
(a) (b) (c) (d)
Rocker
Sheet
Die
2.
(e)
3. 1.
P
counter
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Die-Bending Operations
FIGURE 7.22 Common die-bending operations, showing the die-opening dimension W, used in
calculating bending forces, as shown in Eq. (7.11).
(a) V die (b) Wiping die
W
Punch
Die
W
Bending force:
F
max
=k
(UTS)Lt
2
W
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Press Brake Operations
FIGURE 7.23 (a) through (e) Schematic illustrations of various bending operations in a press
brake. (f) Schematic illustration of a press brake. Source: Courtesy of Verson Allsteel Company.
Die holder
(f)
Connections
Flywheel Main
gear
Main gear
Motor
Clutch and
brake unit
Side
housing
Floor line
Crown
Bed
Ram
Channel
forming
(a)
Joggle
(b)
Hemming
(flattening)
(c)
Two-stage lock seam
(d)
Offset forming
(e)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Bending Operations
FIGURE 7.25 (a) Bead forming with
a single die. (b)-(d) Bead forming
with two dies in a press brake.
(c)
(a) (b)
Bending in a 4-slide machine
Roll bending
Driven
rolls
Adjustable
roll
(d)
Sheet
Polyurethane
roll
Punch
Die
Air bending
FIGURE 7.24 Examples of various bending operations.
(a) (b) (c) (d)
Formed bead
Die
(a) (b) (c) (d)
1. 2.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Flanging Operations
FIGURE 7.26 Illustrations of various
anging operations. (a) Flanges formed on
at sheet. (b) Dimpling. (c) Piercing sheet
metal with a punch to form a circular
ange. In this operation, a hole does not
have to be prepunched; note, however, the
rough edges along the circumference of the
ange. (d) Flanging of a tube; note the
thinning of the periphery of the ange, due
to its diametral expansion.
(a)
(c)
(b)
(d)
Stretch flange
Straight flange
Shrink flange
Reverse flange
Joggled flange
Slug
Piercing punch
Spring-loaded stripper
Sheet
Die block or die button
Spring-loaded
pressure bushing
Piercing punch
(retracted)
Stripper
plate
Sheet
Die
After
Before
Flange
Tube
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Roll-Forming
FIGURE 7.27 (a) The roll-forming operation, showing the stages in roll forming of a structural shape.
(b) Examples of roll-formed cross-sections. Source: Courtesy of Sharon Custom Metal Forming, Inc.
(a) (b)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Bending and Forming Tubes
FIGURE 7.28 Methods of bending tubes.
Using internal mandrels, or lling tubes
with particulate materials such as sand,
prevents the tubes from collapsing during
bending. Solid rods and structural shapes
are also bent by these techniques.
Mandrels for
tube bending
(d)
Stretch
bending
(a)
Draw
bending
(b)
Compression
bending
(c)
Plug
Balls
Laminated
Cable
Clamp
Form block
(rotating)
Pressure bar
Chuck
Chuck Workpiece
Form
block
(fixed)
Form block
(fixed)
Wiper
shoe
Clamp
FIGURE 7.29 A method of forming a tube with sharp angles, using an
axial compressive force. Compressive stresses are benecial in forming
operations because they delay fracture. Note that the tube is supported
internally with rubber or uid to avoid collapsing during forming. Source:
After J.L. Remmerswaal and A. Verkaik.
Die
Punch
Tube
Rubber or fluid
Stops
Die
Punch
1. 2.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Stretch-Forming
FIGURE 7.30 (a) Schematic illustration of a stretch-forming operation. Aluminum skins for aircraft
can be made by this process. Source: Cyril Bath Co. (b) Stretch forming in a hydraulic press.
Crosshead
Ram
Upper tool
Clamping fixture
Workpiece
Lower tool
Bed
1. 2. 3.
(b)
Stretching
(a)
Table-mounted
gripper
Tool Workpiece Stretch gripper
Adjustable
slide
Turntable
Hydraulic
stretching
unit
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Bulging
FIGURE 7.32 (a) Bulging of a tubular part with a exible plug. Water pitchers can be made by this method. (b)
Production of ttings for plumbing by expanding tubular blanks with internal pressure; the bottom of the piece is
then punched out to produce a T section. Source: After J.A. Schey. (c) Sequence involved in manufacturing of a metal
bellows.
(b)
(a)
(c)
Before After
Ring
Punch
Knockout
rod
Rubber plug
Die insert
Two-piece die
(hinged)
Fluid
Die
Fluid
Workpiece
Compressed tube Bulged tube
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Forming with a Rubber Pad
FIGURE 7.33 Examples of bending and embossing sheet metal with a metal punch and a
exible pad serving as the female die. Source: Polyurethane Products Corporation.
(c) (a) (b)
Metal punch
Polyurethane pad
Blank
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Sheet Hydroforming
FIGURE 7.34 The principle of the hydroform process, also called uid forming.
Pressure-control valve
Rubber diaphragam
Draw ring
Punch
Blank
Forming cavity (oil filled)
1.
2. 3. 4.
Part
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Tube Hydroforming
FIGURE 7.35 (a) Schematic illustration of the tube hydroforming process. (b) Example of tube hydroformed parts.
Automotive exhaust and structural components, bicycle frames, and hydraulic and pneumatic ttings can be
produced through tube hydroforming. Source: Schuler GmBH.
(a) (b)
Horizontal
cylinder
Die holder
plate
Cylinder
holder
bracket
Die holder
plate
Slide plate Centering
Bed plate Hydroformed part
Top die
Seal
punch
Bottom
die
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Spinning
FIGURE 7.36 Schematic illustration of spinning processes: (a)
conventional spinning, and (b) shear spinning. Note that in shear
spinning, the diameter of the spun part, unlike in conventional
spinning, is the same as that of the blank. The quantity f is the feed
(in mm/rev or in./rev).
(a)
Mandrel
Blank
Roller
Cone
to
t
f

(b)
Tool
Mandrel
Blank
FIGURE 7.37 Typical shapes produced by the
conventional spinning process. Circular marks on
the external surfaces of components usually
indicate that the parts have been made by
spinning, such as aluminum kitchen utensils and
light reectors.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Shear Spinning
FIGURE 7.38 Schematic illustration of a
shear spinnability test. Note that as the
roller advances, the spun part thickness is
reduced. The reduction in thickness at
fracture is called the maximum spinning
reduction per pass. Source: After R.L. Kegg.
t
f
t
o
Mandrel
t
t
o
Blank
!
Spun
piece
Flange
Roller
FIGURE 7.39 Experimental data showing the
relationship between maximum spinning reduction
per pass and the tensile reduction of area of the
original material. See also Fig. 7.15. Source: S.
Kalpakjian.
0 10 20 30 40 50 60 70 80
Tensile reduction of area (%)
100
80
60
40
20
0
M
a
x
i
m
u
m

s
p
i
n
n
i
n
g
r
e
d
u
c
t
i
o
n

p
e
r

p
a
s
s

(
%
)
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8
True strain at fracture in tension (P
f
)
Tube spinning
Shear spinning
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Tube Spinning
FIGURE 7.40 Examples of (a) external and (b) internal tube spinning, and the process variables involved.
(a)
(b)
E
x
t
e
r
n
a
l
Mandrel
Roller
Forward
Workpiece
f
t
o
t
Backward
f
f
Die
f
I
n
t
e
r
n
a
l
F
t
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Incremental Sheet-Metal Forming
FIGURE 7.41 (a) Illustration of an incremental forming operation. Note that no mandrel is used, and
that the nal part shape depends on the path of the rotating tool. (b) An automotive headlight
reector produced through CNC incremental forming. Note that the part does not have to be
axisymmetric. Source: After J. Jesweit.
Clamp
Blank
Rotating
tool
(a) (b)
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Explosive Forming
FIGURE 7.43 Effect of the standoff distance and type of energy-transmitting
medium on the peak pressure obtained using 1.8 kg (4 lb) of TNT. The pressure-
transmitting medium should have a high density and low compressibility. In
practice, water is a commonly used medium.
Explosive Water level
Ground level
Workpiece
Hold-down
ring
Die
Vacuum line
Tank
Standoff
FIGURE 7.42 Schematic illustration of the explosive forming
process. Although explosives are typically used for destructive
purposes, their energy can be controlled and employed in
forming large parts that would otherwise be difcult or
expensive to produce by other methods.
60
50
40
30
20
10
0
P
e
a
k

p
r
e
s
s
u
r
e

(
p
s
i

1
0
3
)
m
0 0.5 1 1.5
400
300
200
100
0
M
P
a
0 1 2 3 4 5
Standoff (ft)
Water
Air
Pressure generated:
p =K

W
R

a
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Electrohydraulic and Magnetic-Pulse
Forming
FIGURE 7.44 Schematic illustration of the
electrohydraulic forming process.
Electrodes
Water
Clamp
Sheet
Die
Switch
Switch
Capacitor bank
Charger
FIGURE 7.45 (a) Schematic illustration of the magnetic-
pulse forming process. The part is formed without
physical contact with any object, and (b) aluminum tube
collapsed over a hexagonal plug by the magnetic-pulse
forming process.
(b) (a)
C
L
Coil current
Eddy current
Coil
Tube
Mandrel
After forming
Before
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Superplastic Forming
FIGURE 7.46 Two types of structures made by combining diffusion bonding and
superplastic forming of sheet metal. Such structures have a high stiffness-to-weight ratio.
Source: Rockwell Automation, Inc.
Mold
Before
After
Product
(a) (b)
Mold
Clamp Stop-off
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Peen-Forming
FIGURE 7.47 Schematic illustration of a peen forming machine to shape a large sheet-metal part, such as
an aircraft-skin panel. Note that the sheet is stationary and the peening head travels along its length.
Source: Metal Improvement Company.
Traversing gantry machine
Stationary workpiece
Track
Track
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Honeycomb Structures
FIGURE 7.48 Methods of making honeycomb structures: (a) expansion process, and (b) corrugation
process; (c) assembling a honeycomb structure into a laminate.
(b)
Roll
Corrugated
block
Corrugated
panel
Corrugated
sheet
Corrugating
rolls
(a)
Adhesive
Roll
Sheet
Block
Expanded
panel
Slice
(c)
Adhesive
impregnated
scrim cloth
(optional)
Face sheet
Expanded
honeycomb
core
Face sheet
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Deep-Drawing
FIGURE 7.49 (a) Schematic illustration of the deep drawing process on a circular sheet-metal blank. The
stripper ring facilitates the removal of the formed cup from the punch. (b) Variables in deep drawing of a
cylindrical cup. Note that only the punch force in this illustration is a dependent variable; all others are
independent variables, including the blankholder force.
R
d
(a) (b)
Punch
Blankholder
force
Blankholder
Blank
Die
(draw ring)
D
p
T
D
o
F
c
R
p
Before After
Punch
Blank holder
Blank
Blank Drawn cup
Die
Spring
stripper ring
Pressure
plate
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Deformation in Flange and Wall
FIGURE 7.50 Deformation of elements in (a) the ange and (b) the cup wall in deep drawing of a cylindrical cup.
(a) (b)
B
A
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Pure Drawing vs. Pure Stretching
FIGURE 7.51 Examples of (a) pure drawing and (b) pure stretching; the bead prevents the sheet
metal from owing freely into the die cavity. (c) Unsupported wall and possibility of wrinkling of
a sheet in drawing. Source: After W.F. Hosford and R.M. Caddell.
(c) (b) (a)
Unsupported
wall
Punch
Blankholder
force
Die Die
A
A!
Blankholder
Punch
Die
Deforming
area
Failure
Bead
Deforming
area
Failure
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Draw Beads & Metal Flow
FIGURE 7.52 (a) Schematic illustration of a draw bead. (b) Metal ow during drawing of a
box-shaped part, using beads to control the movement of the material. (c) Deformation of
circular grids in drawing. (See Section 7.7.)
Draw bead
Die
Bead
Bead
Original
blank
edge
Bend-and-
straighten
Deep
draw
Blank
edge after
drawing
Bead
C
L
C
L
Zero minor
strain
(a) (b) (c)
Punch
Blankholder
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Ironing
FIGURE 7.53 Schematic illustration of the ironing process. Note that the cup wall is thinner
than its bottom. All beverage cans without seams (known as two-piece cans) are ironed,
generally in three steps, after being deep drawn into a cup. Cans with separate tops and bottoms
are known as three-piece cans.
Punch
Die
Cup
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Anisotropy
FIGURE 7.54 Denition of the normal
anisotropy, R, in terms of width and thickness
strains in a tensile-test specimen cut from a
rolled sheet. Note that the specimen can be
cut in different directions with respect to the
length, or rolling direction, of the sheet.
R =

t

w

l
Material

R
Zinc alloys 0.4-0.6
Hot-rolled steel 0.8-1.0
Cold-rolled rimmed steel 1.0-1.4
Cold-rolled aluminum-killed steel 1.4-1.8
Aluminum alloys 0.6-0.8
Copper and brass 0.6-0.9
Titanium alloys () 3.0-5.0
Stainless steels 0.9-1.2
High-strength low-alloy steels 0.9-1.2
TABLE 7.3 Typical range of the average normal
anisotropy ratio, R, for various sheet metals.
Normal anisotropy:
Planar anisotropy:
R =
!
w
!
t
=
ln

w
o
w
f

ln

t
o
t
f

Average anisotropy:

R =
R
0
+2R
45
+R
90
4
!R =
R
0
2R
45
+R
90
2
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Anisotropy and Effects
FIGURE 7.55 Effect of grain
size on the average normal
anisotropy for various low-
carbon steels. Source: After
D.J. Blickwede.
4 6 8 10 12
2.6
3.0
1.8
2.2
1.4
1.0
ASTM grain number
R
i
m
m
e
d
A
l
u
m
i
n
u
m
-
k
i
l
l
e
d
I
n
t
e
r
s
t
i
t
i
a
l
-
f
r
e
e
A
v
e
r
a
g
e

n
o
r
m
a
l

a
n
i
s
o
t
r
o
p
y

(
R
)
FIGURE 7.56 Effect of average normal
anisotropy, R on limiting drawing ratio
(LDR) for a variety of sheet metals.
Source: After M. Atkinson.
4.0
3.0
2.0
1.0
L
i
m
i
t
e
d

d
r
a
w
i
n
g

r
a
t
i
o

(
L
D
R
)

0.2 0.4 0.6 1.0 2.0 4.0 6.0
Average strain ratio (R
avg
)
Copper,
brass,
aluminum
Steel
Titanium
Zinc
FIGURE 7.57 Typical earing in a
drawn steel cup, caused by the
planar anisotropy of the sheet
metal.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Punch Force
FIGURE 7.58 Schematic illustration of the
variation of punch force with stroke in deep
drawing. Arrows indicate the initiation of
ironing. Note that ironing does not begin until
after the punch has traveled a certain distance
and the cup is partially formed.
Ironing
Increasing
clearance
P
u
n
c
h

f
o
r
c
e

(
F
)
Stroke
Maximum punch force:
F
max
=!D
p
t
o
(UTS)

D
o
D
p
0.7

FIGURE 7.59 Effect of die and punch corner radii on fracture

in deep drawing of a cylindrical cup. (a) Die corner radius too
small; typically, it should be 5 to 10 times the sheet thickness.
(b) Punch corner radius too small. Because friction between
the cup and the punch aids in the drawing operation,
excessive lubrication of the punch is detrimental to
drawability.
Punch
corner radius
(a) (b)
Die corner
radius
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Redrawing & Tractrix Die
FIGURE 7.60 Reducing the diameter of drawn cups
by redrawing operations: (a) conventional redrawing,
and (b) reverse redrawing. Small-diameter deep
containers may undergo several redrawing
operations.
Cup partially
redrawn
Die
Drawn cup
Blankholder
Punch
(a) Conventional redrawing (b) Reverse redrawing
Punch
Blankholder
Drawn cup
Die
Cup partially
redrawn
FIGURE 7.61 Stages in deep drawing without a
blankholder, using a tractrix die prole. The tractrix is
a special curve, the construction for which can be
found in texts on analytical geometry or in
handbooks.
Punch
1. 2.
Sheet
Die
3.
Cup
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Punch-Stretch Test
FIGURE 7.62 Schematic illustration of the punch-stretch test on sheet specimens with different
widths, clamped along the narrower edges. Note that the narrower the specimen, the more
uniaxial is the stretching. (See also Fig. 7.65.)
Bead
Sheet
Punch
Sheet width
Bead
(a) Side view (b) Top view
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Forming Limit Diagram
FIGURE 7.63 (a) Forming-limit diagram (FLD) for various sheet metals. Note that the major strain is always positive. The region
above the curves is the failure zone; hence, the state of strain in forming must be such that it falls below the curve for a
particular material; R is the normal anisotropy. (b) Illustrations of the denition of positive and negative minor strains. If the area
of the deformed circle is larger than the area of the original circle, the sheet is thinner than the original thickness because the
volume remains constant during plastic deformation. Source: After S.S. Hecker and A.K. Ghosh.
(a) (b)
Major strain,
positive After
stretching
Minor
strain,
positive
Major strain
Minor
strain
Minor
strain,
negative
Before
stretching
Minor strain (%)
M
a
j
o
r

s
t
r
a
i
n

(
%
)
Simple
tension
(for R = 1)
Pure
shear
Failure
zone
Safe zone
260 240 220 0 20 40 60 80
0
20
40
60
80
100
120
140
High-strength
steel
Aluminum alloy
Low-carbon
steel
Brass
Plane strain
Equal (balanced)
biaxial
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Formability Testing
FIGURE 7.64 An example of the use of grid
marks (circular and square) to determine the
magnitude and direction of surface strains in
sheet-metal forming. Note that the crack
(tear) is generally perpendicular to the major
(positive) strain. Source: After S.P. Keeler.
FIGURE 7.65 Bulge test results on steel sheets of various widths.
The rst specimen (farthest left) stretched farther before cracking
than the last specimen. From left to right, the state of stress
changes from almost uniaxial to biaxial stretching. Source:
Courtesy of Ispat Inland, Inc.
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Strains in an Automobile
FIGURE 7.66 Major and minor strains in various regions of an automobile body.
M
a
j
o
r

s
t
r
a
i
n

(
%
)
10
8
6
4
2
0
24 22 0 2 4
Minor strain (%)
M
a
j
o
r

s
t
r
a
i
n

(
%
)
10
8
6
4
2
0
24 22 0 2 4
Minor strain (%)
M
a
j
o
r

s
t
r
a
i
n

(
%
)
10
8
6
4
2
0
24 22 0 2 4
Minor strain (%)
1
3
5
7
Trunk lid Roof Front door
1
5
9
1
3
5
7
M
a
j
o
r

s
t
r
a
i
n

(
%
)
10
8
6
4
2
0
24 22 0 2 4
Minor strain (%)
Front fender
1
3
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Design Considerations
FIGURE 7.67 Efcient nesting of parts for
optimum material utilization in blanking.
Source: Society of Manufacturing Engineers.
13.2 mm
43.2 mm
39.6 mm
11.4 mm
Poor Better
FIGURE 7.68 Control of tearing and buckling of a ange in a
right-angle bend. Source: Society of Manufacturing Engineers.
Poor Better Best
(a)
(b)
3 x sheet
thickness
Relief
notch
Closed
corner
Closed corner 3 x sheet
thickness
Relief notch
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Design Considerations (cont.)
FIGURE 7.69 Application of notches to avoid
tearing and wrinkling in right-angle bending
operations. Source: Society of Manufacturing
Engineers.
(a)
(b) (c)
Notch Tearing
Notch
Poor Good
Poor Good
Poor Good
FIGURE 7.70 Stress concentrations near bends. (a) Use of a
crescent or ear for a hole near a bend. (b) Reduction of the severity
of a tab in a ange. Source: Society of Manufacturing Engineers.
(a) (b)
Poor
Better
x
R
Bend line
x
Poor Good
Bend line
R
FIGURE 7.71 Application of (a) scoring, or (b) embossing to obtain a
sharp inner radius in bending. However, unless properly designed, these
features can lead to fracture. Source: Society of Manufacturing
Engineers.
Before
After
(a) (b)
Sharp
radius
Sharp
radius
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Economics of Sheet-Metal Forming
FIGURE 7.72 Cost comparison for manufacturing a cylindrical sheet-metal container by
conventional spinning and deep drawing. Note that for small quantities, spinning is more
economical.
0.3 m
diameter
Drawing
1 0 2 3 4 5
Spinning
Number of parts (x 10
3
)
1
0
2
3
4
5
6
7
8
C
o
s
t

p
e
r

p
a
r
t

(
r
e
l
a
t
i
v
e
)
0.19 m
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Cast Study: Drum Cymbals
FIGURE 7.73 (a) A selection of common
cymbals; (b) detailed view of different
surface texture and nish of cymbals. Source:
Courtesy W. Blanchard, Sabian Ltd.
(a) (b)
FIGURE 7.74 (a) Manufacturing
sequence for production of cymbals.
Source: Courtesy W. Blanchard,
Sabian Ltd.
1. As-cast
2. After rolling; multiple
rolling/annealing
cycles necessary
3. Stretch formed
and trimmed
4. Hang hole punched
5. Stretch formed
6. Hammered
7. Lathe-turned
and polished
Manufacturing Processes for Engineering Materials, 5th ed.
Kalpakjian Schmid
2008, Pearson Education
ISBN No. 0-13-227271-7
Cymbal Hammering
FIGURE 7.75 Hammering of cymbals. (a) Automated hammering on a peening
machine; (b) hand hammering of cymbals. Source: Courtesy W. Blanchard, Sabian Ltd.
(a) (b)