Drawing of Automotive Sheet Metal Parts: TALAT Lecture 3705

TALAT Lecture 3705
Drawing of Automotive Sheet Metal Parts

30 pages, 37 figures
Advanced Level
prepared by Klaus Siegert, Institut fr Umformtechnik, Universitt Stuttgart
Objectives:
to describe the special requirements for the successful fabrication of automotive aluminium sheet metal parts with respect to material properties, machinery and drawing
equipment and tools
Prerequisites:
General production engineering background
Background in sheet metal forming principles
TALAT Lectures 3701 - 3704
Date of Issue: 1996

EAA European Aluminium Association
3705 Drawing of Automotive Sheet Metal Parts
Table of Contents
3705 Drawing of Automotive Sheet Metal Parts.............................................2
3705.01 Introduction................................................................................................ 3
3705.02 Characteristic Materials Parameters ....................................................... 4
Effect of Paint Bake Cycle on Strength ...................................................................4
Anisotropy................................................................................................................4
3705.03 The Drawing Process ................................................................................. 6
Stretch Forming .......................................................................................................6
Stretch Forming a Bulge with a Spherical Punch ....................................................7
Hydraulic Stretch Forming.......................................................................................8
Deep Drawing with a Hemispherical Punch ..........................................................10
Deep Drawing and Stretch Forming ......................................................................11
Drawing Irregular Sheet Shapes of Large Areas....................................................12
3705.04 Possibilities of Controlling the Material Flow....................................... 13
Control of Material Flow under Blankholder ........................................................13
Arrangement of Draw Beads..................................................................................15
3705.05 Adjusting the Die Cushion ....................................................................... 15
Mechanical vs. Hydraulic Press Equipment ..........................................................15
Four-Point Die Cushion .........................................................................................16
Desired and Actual Curves for Blankholder Force ................................................17
Advantages of a Servo-Hydraulic Die Cushion in the Press Table .......................17
Four-Point Die Cushion in the Press Table............................................................18
Four-Point Die Cushion in the Press Table with Adjustable Spindle Sleeves.......19
Functional Principle of a Spindle Sleeve Adjustment ...........................................20
Experimental Construction of a Single Action Hydraulic Press (10-Point) ..........20
Blankholder and Spindle Sleeve Forces.................................................................21
Force Displacement Curves ...................................................................................21
Demonstration Case of the Multi-Point Drawing Arrangement ............................24
3705.06 Tool Materials for Drawing of Aluminium Sheet Metal Parts ............ 25
Tool Materials........................................................................................................25
Surface Coatings for Drawing Tools .....................................................................26
3705.07 Examples................................................................................................... 27
3705.08 List of Figures............................................................................................ 29
TALAT 3705
3705.01 Introduction
Forecasts for the year 2000 predict that the proportion of steel used in cars will shrink
compared to 1984. At the same time the proportion of high strength steel will increase
sharply as will the share of automotive aluminium, see Figure 3705.01.01.
Forecast for the Year 2000

%
Steel
65
Steel
60
high-strength
and
higher strength
steel
50
40
30
20
Plastics
Aluminium
Plastics Aluminium
10
0
2000
1984
Source: Thyssen technical reports 2/86
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Forecast for the Year 2000
3705.01.01
Training in Aluminium Application Technologies
Among other applications in the car, aluminium alloys will be used to substitute steel in
carbody sheet components. Previous experience with the production of aluminium sheet
metal components for cars has demonstrated that special attention has to be given to the
peculiarities of aluminium carbody sheet in the fabrication of car components. The fabrication process of carbody sheet metal components is a mixture of deep drawing and
stretch forming. Aluminium and steel behave differently with regard to these two basic
forming operations. It is, therefore, necessary to consider the basic technology of sheet
metal drawing for aluminium carbody components in view of the material properties,
the behaviour during the drawing process and the special requirements with respect to
the drawing equipment and the tooling.
TALAT 3705
3705.02 Characteristic Materials Parameters

Effect of Paint Bake Cycle on Strength
Figure 3705.02.01 shows the influence of cold forming and paint stoving on the yield
stress Rp0,2 of typical aluminium carbody sheet alloys. It is apparent that age-hardening
alloys profit from the baking cycle while strain-hardening alloys may suffer a reduction
in yield strength values.
Influence of Cold Work and Simulated

Lacquer Stoving (205 C/ 30 min.) on Yield Strength
300
6009-T4 after stoving
Yield strength Rp0,2
N/mm
250
6009-T4 before stoving
200
5182-O
150
5182-O after stoving
100
0
4
5
6
Cold Work (Strain)
% 8
Source: IFU Stuttgart

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Influence of Cold Work and Simulated

Lacquer Stoving on Yield Strength
3705.02.01
Anisotropy
Figure 3705.02.02 shows the yield criteria for a plane state of stress as a function of the
r value. A value of r = 1 indicates an isotropic behaviour.
Under a tensile-compressive state of stress, as in the flange of a deep drawn part, the
stress required to maintain a plastic state decreases with increasing values of r. This
means that increasing values of r result in lower drawing forces.
During tensile-tensile stressing, e.g. in the body of a deep drawn part, larger axial
stresses can be transmitted with increasing values of r.
By increasing the value of r, one can increase the strength of the body and at the same
time lower the strength in the flange. This explains why the limiting draw ratio increases
with increasing r values.
TALAT 3705
Aluminium sheet alloys in a state of good drawing quality generally have values of r 1
which vary with respect to the rolling direction.
Effects of Anisotropy
!"
I
! # %&
IV
r=5
r=3
r = 1, r = 0
kf
r=0
-kf
!1
kf
-kf
II
III
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Effect of r-Value on Yield Locus
3705.02.02
Figure 3705.02.03 illustrates the elongation values Ag and A80 for the alloy
AlMgSi1-ka (EN-AW 6082-T4) using polar coordinates.
Elongation Values for AlMgSi1-ka

in polar coordinates
Rolling direction (RD)
0
30
22.5
45
15
67.5
90
to RD
Ag
A80mm
Source: IfU Stuttgart
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Elongation Values for AlMgSi1-ka in Polar Coordinates
3705.02.03
Figure 3705.02.04 shows the vertical anisotropy r for the alloy AlMg5Mn-w (EN-AW
5182-0) using polar coordinates.
TALAT 3705
Vertical Anisotropy r for AlMg5Mn w

as a function of rolling direction
Rolling direction (RD)
0
22.5
45
1.0
67.5
0.4
r90 = 0.640
90
to RD
r0 = rmin' 0.592
r45 = rmax' 0.934
r value for g = 0.11

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Vertical Anisotropy r for AlMg5Mn w

as a Function of Rolling Direction
3705.02.04
The varying elongation behaviour and the varying values for anisotropy are a result of
the texture of the individual materials. The values shown here are exemplary and depend
on the material as well as on the processes of cold and warm rolling and on the heat
treatment.
3705.03 The Drawing Process
Stretch Forming
Basic elements of stretch forming are shown in Figure 3705.03.01. During stretch forming, the sheet is clamped on two sides. As a result, the increase in the sheet surface area
due to the activation of the punch, is accompanied by a decrease in sheet thickness. A
tensile state of stress exists. The forming zone starts at the clamping grips and proceeds
to the punch middle. In order to ensure that, in spite of the hindering action of the friction, even this portion of the sheet is strained, it is desirable to keep the coefficient of
friction between sheet blank and punch low and to have a high strain hardening coefficient.
TALAT 3705
Stretch Forming
Sheet blank
Gripping jaws (clamps)
' Two-sided clamping
Stretching forming punch
' Due to rigid clamping, increase of surface compensated for by decrease in sheet thickness
with little participation of parts not under tension.
' The forming zone spreads out, starting from the end of the gripping jaw to the middle
of the forming punch.
Aims:
' As small a coefficient of friction as possible between sheet and forming punch.
' A high strain hardening coefficient n
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3705.03.01
Stretch Forming
Stretch Forming a Bulge with a Spherical Punch

Figure 3705.03.02: During the stretch forming of a bulge with a spherical punch the
blank is clamped firmly under the blankholder so that no material can flow in from the
flange to supply material for the increasing surface area during drawing. The enlargement of the hemispherical surface area can only be achieved by a decrease in sheet
thickness.
Mechanical drawing
FSt + FK
FSt + FK
Drawing ring
Blankholder
d0
FK
Drawing punch (forming block)
FK
FSt
- Clamping force FK prevents flowing-in of sheet
- All-around clamping
- Forming zone spreads out from clamping location to punch dome
- Increase of surface area compensated for only by decrease in thickness.
Aims: - rmin large
- r small
- n large
Coefficient of friction between sheet and punch should be kept small.

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TALAT 3705
Mechanical Drawing
3705.03.02
The forming zone starts at the clamping grips and proceeds to the spherical punch pole.
For this stretch forming process it is desirable to have as low a value of r as possible
and as high a value of rmin and strain hardening coefficient n as possible. The coefficient
of friction between sheet and punch should be kept low.
Strain-Path Curves for Mechanical Drawing

Stretch forming with a hemispherical punch
Lubricant: uncompounded oil 300 cSt/ 40C
50
point 18
point 15
point 12
point 9
point 6
40
P
FR
12
30
Tear depth 36.5 mm
15
1 [1]
15
Tear
20
12
6
18
10
18
36.5 mm
30 mm
20 mm
10 mm
0
0
10
20
Source: W.Karsunke
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2 [1]
30
40
50
3705.03.03
Figure 3705.03.03 illustrates the traces of the principal strains at different locations of
the drawn bulge during stretch forming with a hemispherical punch. The traces of strain
from locations 9 and 12 approach the forming limit curve closest. Not surprisingly, tearing occurs at a location next to these points on the bulge.
Hydraulic Stretch Forming

During hydraulic drawing, the blank is clamped all around its edges so that the forming
zone is the portion within the drawing ring, see Figure 3705.03.04. Like in the previous
case, the increase in surface area has to be compensated for by a decrease in the sheet
thickness.
As far as the characteristic sheet values are concerned, large values for rmin and low
values for r are desirable. The strain hardening coefficient n should be as high as possible.
TALAT 3705
Hydraulic
drawing
FK + Fu
FK + Fu
d0
Drawing ring
Base plate
PHydr.
FN + Fu
Fu = PHydr.
FN + Fu
2
d0
4
- Clamping force FK prevents flowing-in of sheet

- All-around clamping
- Forming zone equal to sheet region included in drawing ring
- Increase of surface area compensated for only by decrease in thickness.
Aims:
large
small
large
- rmin
- r
-n
Source:IFU Stuttgart
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Hydraulic Drawing
3705.03.04
Figure 3705.03.05 illustrates the traces of the principal strains at different locations on
the drawn part during hydraulic stretch forming. One notices that the differences between the individual measuring locations is much smaller than for mechanical buldge
drawing, indicating that the deformation strain is much more uniformly distributed over
the component.
Strain-Path Curves for Hydraulic Drawing

50
18
point 18
point 15
point 12
point 9
point 6
40
15
Tear
1 [1]
30
Tear depth 36.5 mm

15
12
12
20
9
18
36.5 mm
30 mm
20 mm
6
6
10
10 mm
0
0
10
Source: W.Karsunke
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20
2 [1]
30
40
TALAT 3705
50
3705.03.05
In Figure 3705.03.06, the principal strains g for mechanical and hydraulic drawing are
compared.
Comparison of the Principal Strains g

for Mechanical and Hydraulic Drawing
1.00
g [1]
0.80
10 cSt/40C
Stretch forming
100 cSt/40C with hemispherical
300 cSt/40C punch
hydraulic drawing
0.60
0.40
18
0.20
30 mm
1
35
1
5 10 15 18 20 25 30 35
Location of measuring points over hemisphere
100
Source: W.Karsunke
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Comparison of the Principal Strains g

for Mechanical and Hydraulic Drawing
3705.03.06
Deep Drawing with a Hemispherical Punch

Figure 3705.03.07: In deep drawing with a hemispherical punch, the forming zone
covers the region between the flange outer edge and the location where the drawing part
leaves the drawing ring curvature. In contrast to stretch forming, the surface areas of the
blank and the drawn part are about the same, so that the sheet thickness remains almost
constant.
The blankholder force prevents the formation of type 1 folds. The base of the drawing
part is formed according to the principle of mechanical drawing.
As far as the characteristic sheet values are concerned, large values for rmin and low
values for r are desirable. The strain hardening coefficient n should be as high as possible.
The coefficients of friction for the combinations punch/lubricant/sheet, blankholder/
lubricant/sheet, drawing ring/lubricant/sheet and drawing ring rounding/lubricant/sheet
should be as low as possible.
TALAT 3705
10
Deep Drawing
with a
hemispherical punch
FSt + FN
FSt + FN
Drawing ring
d0
D
- blankholder force FN prevents

type 1 folds.
FN
FN
- Forming zone is the sheet area between

flange outer diameter (D = f(h))
and the location at which the sheet
leaves the drawing ring curvature (d0).
- Surface area of drawn part is
approximately equal to the surface area
of the original blank. Consequently,
sheet thickness is almost constant.
- Dome (bottom of part) is formed
by stretch forming
FSt
Aims: - rmin
- r
-n
Blankholder
Drawing punch
large
small
large
Coefficients of friction should be kept small

for the following combinations:
hemisspherical punch surface / lubricant / sheet,
blankholder / lubricant / sheet,
drawing ring / lubricant / sheet and
drawing ring rounding / lubricant / sheet.

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3705.03.07
Deep Drawing and Stretch Forming

Figure 3705.03.08 shows two separate schematics for the comparison of the deep drawing and stretch forming processes for a flat bottomed cup.
Deep drawing and stretch forming
Deep drawing
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TALAT 3705
Stretch forming
11
3705.03.08
Sheet metal parts with large surface areas are usually formed using a combination of
deep drawing and stretch forming.
A state of pure stretch forming exists only in very few cases. In such cases, the outer
edge of the blank is clamped so that the increase in surface area can only come out of
the sheet thickness.
Deep drawing is the other extreme in which the blankholder holds the sheet so that it
can flow in during forming. The sheet thickness remains approximately constant and the
surface areas of the shaped part and the starting blank are about the same.
Drawing Irregular Sheet Shapes of Large Areas

Two types of drawing beads are shown in the Figure 3705.03.09. The clamping beads
have a rectangular section and absolutely prevent any sheet material from flowing in.
Brake rolls serve only to create an additional forming work.
Blank form
Drawing frame
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TALAT 3705
12
3705.03.09
3705.04 Possibilities of Controlling the Material Flow
In processes which are not purely deep drawing but consist instead of a combination of
deep drawing and stretch forming, it is necessary to control the flow of material under
the blankholder. This can be achieved using different methods, individually or in combinations.
Control of Material Flow under Blankholder
Control of material flow

under the blankholder
Blank form
Lubricant
Crimp
Influence of
frictional forces
Blankholder force
FN
drawing crimp
- type
- amount
- distribution
Draw path
clamping crimp

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Control of Material Flow Under Blankholder
3705.04.01
Figure 3705.04.01 shows a number of possibilities for controlling material flow under a
blankholder:
Blank form
Large sheet blank areas under the blankholder require large forming forces.
Lubricants
One method is to use a blank with nonuniform lubrication, i.e, different lubrication conditions at different locations of the blank, before drawing. Another method is to use a
blank with a uniform basic lubrication which is then locally enhanced at chosen places
by lubricating jets arranged in the tool, i.e., before each pressing stroke, an additional
local lubrication effect exists between sheet and work-piece.
TALAT 3705
13
Clamping crimps
Clamping crimps hinder the flowing in of the material to varying degrees, depending on
the form and size. It is thus possible to reduce the blankholder force, whereby the drawing force is increased.
Influencing the frictional forces
By regulating the blankholder force, it is possible to enhance or hinder the flow of material under it. This effect is obtained by locally varying the distance between blankholder
and drawing frame, so that higher contact pressures can be brought to bear where the
distance is smaller.
Another possibility of controlling the material flow and consequently the deformation
strain distribution during the drawing of irregular sheet shapes with varying draw
depths, is by using brake rolls and draw beads. These hinder the flow of material by
varying amounts, depending on their form and size. Again, it is possible to reduce the
blankholder force, whereby the drawing force increases.
As a result of the brake action of the draw beads, the material can no longer freely flow
over the draw ring radius into the draw gap during the forming process. Thus it is possible to reduce the stress differences between side walls and corner regions for complicated irregular shapes as well as for square shaped drawn parts.
By optimally arranging the draw beads, one can control the material flow to create a
uniform stress distribution such as occurs while fabricating cylindrical shapes. Brake
rolls and draw beads ensure that the resistance of material flow over the draw ring radius
into the draw gap varies locally, thus simulating the effect of increasing blankholder
pressure.
Depending on the design and arrangement in the tool, one can differentiate between
draw beads and brake rolls.
Draw beads are arranged at some distance from the drawing ring radius and cause, together with the die radius, a three-fold directional change of the sheet. Draw beads can
be arranged in both slanting and straight blankholder surfaces.
Brake rolls are arranged at the die shoulder and create a two-fold directional change of
the sheet material. Brake rolls in the draw ring are used mostly for round or oval sheet
shapes with a parabolic or similar casing form.
TALAT 3705
14
Arrangement of Draw Beads

Figure 3705.04.02 shows the arrangement of draw beads for a drawn carbody component.
Arrangement of draw beads

10
10
10

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3705.04.02
3705.05 Adjusting the Die Cushion
Mechanical vs. Hydraulic Press Equipment

During drawing with a mechanical double-acting press (press with drawing punch ram
and blankholder ram), the blankholder can be locally adjusted at the four points under
the crank so that different contact pressures can be applied at the locations front left,
front right, rear left and rear right under the blankholder, Figure 3705.05.01. A regulation, if at all possible, can only be carried out as far as the pressure is concerned.
With the double-acting hydraulic press it is possible, without any great effort, to regulate
the blankholder force during the draw path at each corner point, since each corner point
has its own hydraulic cylinder.
TALAT 3705
15
Double action press
Single action press

with pneumatic drawing
equipment in the press table
Single action press

with hydraulic drawing
equipment in the press table
4x
~ 20 x
a) Ram b) Blankholder ram
c) Drawing punch
d) Blankholder
f) Mounting plate
g)Hydraulic cylinder h) Air-cushion pins
e) Counter pressure

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Drawing Equipment
3705.05.01
Four-Point Die Cushion
Four-point drawing equipment

press ram
tool top part
blank
bottom drawing frame
(blankholder)
drawing tool
tool plate
tool mounting plate
table plate
hydraulic cylinder (4x)
proportional valve

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TALAT 3705
Four-Point Drawing Equipment
16
3705.05.02
Figure 3705.05.02 together with the Figure 3705.05.01 illustrate that it is possible to
draw parts using a three-piece tool not only with a two-fold acting press but also with a
simple acting press. In these cases, the blankholder (lower drawing frame) is supported
on a drawing form plate (cushion) form with the help of a number of pressure bolts.
This drawing form plate is moved up and down or subjected to the blankholder force
with the help of pneumatic or hydraulic cylinders.
Desired and Actual Curves for Blankholder Force
Required curve
Actual curve
210
120
120 135
Source: IfU, Stuttgart
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Force [kN]
1000
900
800
700
600
500
400
300
200
100
0
1000
900
800
700
600
500
400
300
200
100
0
Force [kN]
Force [kN]
Force [kN]
When the top frame contacts the blank lying on the lower frame, an undesirable force
peak occurs, causing the lubricant film to break down, Figure 3705.05.03. In addition,
this causes an undesirable overloading of the tool and machine and is a cause of noise.
This undesirable force peak can be avoided by starting the drawing process with a lower
pressure in the cylinders and then increasing this pressure to a level which prevents the
formation of type-1 folds and allows the necessary material flow to be regulated.
1000
900
800
700
600
500
400
300
200
100
0
1000
900
800
700
600
500
400
300
200
100
0
Required curve
Actual curve
60
15
Ram path
before UT [mm]
210
120
60
15
Ram path
before UT [mm]
150
165
180
UT
Crank angle []
120
135
150
165
180
UT
Crank angle []
3705.05.03
Advantages of a Servo-Hydraulic Die Cushion in the Press Table

Figure 3705.05.04 summarises the advantages of a die cushion in the press table of a
simple acting press over the mechanical double acting press with a drawing ram and a
blankholder ram:
No overturning operations required between drawing press and trimming press
necessary.
TALAT 3705
17
Reduction of the force peaks during initial contact between the top frame and the
sheet blank lying on the bottom frame.
Control of the blankholder force, i.e., the material flow over the draw path.
Reproducible press operation
Advantages of a Servo Hydraulic Die Cushion

in the Press Table
A servo hydraulic die cushion in the press table of a simply acting press table
has following advantages over a two-fold acting mechanical press with drawing
ram and blankholder ram :
1. No overturning operations required between drawing press and trimming press.
2. Reduction of the force peak during contaction of the top frame and sheet blank
lying on the bottom frame.
3. Control of the blankholder force, i.e., the material flow over the draw path.
4. Reproducible press operation.
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Advantages of a Servo Hydraulic Die Cushion

in the Press Table
3705.05.04
Four-Point Die Cushion in the Press Table
Four-point die cushion in the press table with

individually controlled and regulated hydraulic cylinders
Tool mounting
plate
Table plate
Hydraulic
cylinder
Proportional valve

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3705.05.05
The present trend is to produce large one-piece pressed shapes, e.g. complete automobile side walls. Conventional four-point die cushion is, however, unsuitable for large
parts. One method of developing the die cushion is the possibility of utilising many cylinders instead of four corner cylinders, Figure 3705.05.05. In order to prevent the regu-
TALAT 3705
18
lating and control mechanism from getting too complicated, the cylinders can be joined
together in groups which are controlled in unison.
Four-Point Die Cushion in the Press Table with Adjustable Spindle Sleeves
The Institut fr Umformtechnik (institute for forming technology) of the University of
Stuttgart and the company Maschinenfabrik Mller-Weingarten have developed an alternative method. In the construction shown in this Figure 3705.05.06 and Figure
3705.05.08, the force for the blankholder in the drawing frame is controlled by spindle
sleeves with integrated force gauges in which the spindle sleeves can be adjusted to different heights using a stored programme. The spindle sleeves are supported on a drawing cushion which can be regulated and controlled by four hydraulic cylinders.
Spindle sleeve (pressure bolt)

Table plate
Spindle sleeve (presssure bolt)
adjustment
Die cushion plate
Guide for due cushion plate
Hydraulic cylinder
Proportional valve

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Four-Point Die Cushion in a Press Table with

Adjustable Spindle Sleeves
3705.05.06
With this design it is possible to maintain the reliable adjustment of the force-path curve
for each corner cylinder. By choosing the spindle sleeve to be activated, an adjustment
can be made to suit the drawing frame form. The spindle sleeves not required can remain in their normal position. By choosing the optimal spindle sleeve lengths, the tool
can be elasticly bent to compensate for the flexure of the drawing frame and drawing
cushion plate as well as for regulating the material flow by locally adjusting the contact
pressure.
TALAT 3705
19
Functional Principle of a Spindle Sleeve Adjustment

Figure 3705.05.07: The adjustable spindle sleeves are supported against pressure
gauges fitted on the drawing cushion plate. The spindle sleeves are adjusted by hydro
motors, belt drive and spline shaft, whereby the height adjustment is recorded on a moment controller.
Functional principle of a spindle sleeve adjustment
Spindle sleeve (pressure bolt)
Table plate
Spindle sleeve adjusting spindle

Force gauge
Drawing cushion plate
Spline shaft
Toothed belt drive

Moment controller
Hydro motor
Source: IFU Stuttgart, Mller-Weingarten AG
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3705.05.07
Experimental Construction of a Single Action Hydraulic Press (10-Point)

Figure 3705.05.08 shows the experimental construction of a single action hydraulic
press with a 10-point die cushion in the press table. For details refer to Figure
3705.05.06.
Experimental Construction of a
Single Action Hydraulic Press (10-Point)
extension gauges for
punch force
measurement
inductive path gauge

with feeler pin for
folds measurement
extension gauges for
flexure measurement
spindle sleeves (10)

force gauge for
measuring
blankholder force
drawing tool
hydraulic die
cushion
press table
fixing elements

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TALAT 3705
Experimental Construction of a
Single Action Hydraulic Press (10-Point)
20
3705.05.08
Blankholder and Spindle Sleeve Forces

Figure 3705.05.09 shows the blankholder and spindle sleeve forces acting on the drawing cushion plate of a 10-point die cushion based on the principle of four corner point
cylinder forces Fvl (front left), Fvr (front right), Fhl (rear left) and Fhr (rear right). The
sum of these forces is equal to the sum of the active spindle sleeve forces FP1 to FP10.
Blankholder and spindle sleeve forces of a die

cushion plate of a 10-point drawing equipment
PN
Lower drawing frame
FP10
FP5
FP6 FP7
FP8
FP4
FP3
FP9
FP2
Fhl
Fvl
FP1
Fhr
Die cushion plate
Fvr
FVl......Fhr : Controllable and adjustable blankholder forces

FP1.....FP10: Adjustable spindle sleeve forces
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3705.05.09
Force Displacement Curves

Figure 3705.05.10 shows the force-displacement curves of the total blankholder force
FNtot (upper diagram) as well as for the four different blankholder forces (Fvr, Fhr, Fvl,
Fhl), which were pre-set in a five-step rising gradient, over the full drawing path. Furthermore, it also shows the force-displacement curves for the four active spindle sleeves
( FP1, FP2, FP3, FP4) as a function of the drawing path. The formation of force peaks was
largely prevented by correctly pre-setting the individual force-displacement curves for
the four active spindles.
TALAT 3705
21
Force-Stroke Curves
Total blankholder force
Spindle sleeve force
FNges
800
kN
FP2
kN
FP9
200
FP4
100
FP7
600
50
400
100
150
mm
Blankholder force
200
kN
Fvr
200
Fhr
100
Fvl
Fhl
0
50
100
150
mm
200
200
50
100
Stroke
150
mm
200
Stroke
Source: IFU, Stuttgart

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Force-Stroke Curves
3705.05.10
Figure 3705.05.11 shows the hydraulic simple-acting 4,000 kN press supplemented by a

10-point die cushion at the Institute of Forming Technology (IFU) of the University of
Stuttgart.
Hydraulic 4.000 kN
Sheet Forming Press
at the
Institut fr Umformtechnik,
University of Stuttgart
Source: Mller-Weingarten Co.

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Hydraulic 4.000 kN Sheet Forming Press
TALAT 3705
22
3705.05.11
The characteristics of a multi-point die cushion in the press table of a simple-acting

press with respect to the drawing process are summarised in Figure 3705.05.12.

of a Simple Acting Press
' Force application to the blankholder can be adjusted to be
most suitable for the tool.
' Material flow controlled by a defined elastic flexure of the
blankholder using a stored programmable height adjustment
of the spindle sleeves.
' Control and regulation of the blankholder force over the
stroke using four hydraulic cylinders and the proportional
valve technology.
' Reproducible operational behaviour of the die cushion.
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Four-Point Die Cushion in the Press Table of a

Simple Acting Press
3705.05.12
Figure 3705.05.13 gives an example of a lower drawing frame.
Lower drawing frame ( I )
840
1700

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TALAT 3705
Lower Drawing Frame ( I )
23
3705.05.13
Demonstration Case of the Multi-Point Drawing Arrangement

Figure 3705.05.14 shows the lower drawing frame with a four-point force transmission
for the forming of a rectangular cup. The flexural elastic deformation of this four-point
drawing frame can of course be simulated by FE-calculations.
Lower Drawing Frame (II)

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3705.05.14
1200
Tears
KN
FP6
FP7
FP8
FP9
FP10
1000
900
FP5
800
Total blankholder force
FP4
FP3
uniform
force level
FP2
FP1
Extension
of the
working
range
optimal spindle
sleeve height
700
600
500
400
Working range
for good parts
300
200
100
0
Type 1 folds
0
20
40
60
80
100
120
140 mm 180
punch stroke

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Optimal Working Range for Deep Drawing
3705.05.15
Figure 3705.05.15 shows that the working range for deep drawing can be extended considerably by the adjustment of the local blankholder pressure with the aid of the spindle
TALAT 3705
24
sleeves in a multi-point die cushion. The necessary adjustment of the blankholder force
distribution depends on the specific tool geometry and can be determined for each drawing tool. The lower limit of the working range is a consequence of the formation of
type 1 folds in the draw part flange. The upper limit of the working range is a consequence of the formation of tears in the region of the drawn part body. This working
range has to be determined anew for each sheet-lubricant combination.
With an optimal adjustment of the spindle sleeves in a multiple point die cushion, it is
possible to widen the working range for deep drawing and increase the draw depth.
3705.06 Tool Materials for Drawing of Aluminium Sheet Metal Parts
Tool Materials
Figure 3705.06.01 lists typical tool materials for drawing automotive steel and aluminium sheet metal parts. As in the case of steel, the drawing tools for aluminium are of
grey cast iron quality. Experience has shown, however, that the surfaces of such materials are not suitable for forming aluminium. The materials 1.0443 (GS 45) as well as
1.2769 (GS 45 Cr Ni Mo 4 2) are more suitable, since better surface finishes can be obtained, which in turn reduce the tendency for wear and cold weld adhesion. The aluminium bronze AMPCO also has very good gliding properties.
Tool Materials
Steel sheet:
0.6025 (GG 25 Cr Mo)
1.2080 (X 210 Cr 12)
1.2379 (X 155 Cr V Mo 12 1)
Aluminium:
1.0443 (Gs 45)
1.2769 (G 45 Cr Ni Mo 42)
The tool materials listed for aluminium allow a better surface finishing
so that the tendency for cold welding is reduced.
Source: Haller
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TALAT 3705
Tool Materials
25
3705.06.01
Surface Coatings for Drawing Tools

Surface treatments are being increasingly used to improve the wear resistance and to
prevent or reduce the possibility of cold welding as well as to improve the gliding characteristics. In addition to the classical processes of hardening, case hardening, nitriding,
boriding and hard chromium plating, there is an increasing tendency to use hard compound layers based on titanium nitride (TiN) and titanium carbide (TiC). Such layers are
applied using either the chemical vapour deposition (CVD) or the physical vapour deposition (PVD) process, see Figure 3705.06.02. Coatings deposited using the PVD process are gaining in popularity, since the process reaction temperature of maximum 550
C is far below the tempering temperature of the tool steel used.
Surface Treatment Processes

PowderSalt bath
Nitriding
(Nitrocarburising)
Reaction
layers
Powder-
Boriding
PastesVanadising
Ion implanting
Coatings
GasPlasma-
TD process
VD process
mainly N
Applied
layers
Hard chromium
plating
CVD process
W2C
TiC
TiN
TiC + TiN
CrxCy
PVD process
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Surface Treatment Processes
TiN
3705.06.02
Through the use of coatings, it is possible to utilise the properties of both the protective
coating and the base material. The protective coating increases the wear resistance and
the base material absorbs the mechanical stresses without affecting the coating.
TALAT 3705
26
3705.07 Examples
Figure 3705.07.01: CAD depiction of a coup door planking
CAD illustration of a coup door planking

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CAD Illustration of a Coup Door Planking
3705.07.01
Figure 3705.07.02: Designing surfaces
Designing surfaces

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Designing Surfaces
TALAT 3705
27
3705.07.02
Figure 3705.07.03: CAD depiction of edge "B" of the drawing punch surface
CAD illustration of edge ''B''

of the drawing punch surface

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CAD Illustration of edge ''B'' of the Drawing Punch Surface
3705.07.03
Figure 3705.07.04: Considering springback in the design
Considering springback in the design

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Considering Springback in the Design
3705.07.04
The a.m. Figures are all examples of computer assisted designing of body parts.
TALAT 3705
28
3705.08 List of Figures
Figure No. Figure Title (Overhead)

3705.01.01 Forecast for the Year 2000
3705.02.01
3705.02.02
3705.02.03
3705.02.04
3705.03.01
3705.03.02
3705.03.03
3705.03.04
3705.03.05
3705.03.06
Influence of Cold Work and Simulated Lacquer Stoving on Yield

Strength
Effect of r-Value on Yield Locus
Elongation Values for AlMgSi1-ka in Polar Coordinates
Vertical Anisotropy r for AlMg5Mn-w as a Function of Rolling Direction
3705.03.07
3705.03.08
3705.03.09
Stretch Forming
Mechanical Drawing
Hydraulic Drawing
Comparison of the Principal Strains g for Mechanical and Hydraulic
Drawing
3705.04.01
3705.04.02
Control of Material Flow under Blankholder

3705.05.01
3705.05.02
3705.05.03
3705.05.04
3705.05.05
3705.05.06
3705.05.07
3705.05.08
3705.05.09
3705.05.10
3705.05.11
3705.05.12
3705.05.13
3705.05.14
3705.05.15
Drawing Equipment
Four-Point Drawing Equipment
Advantages of a Servo Hydraulic Die Cushion in the Press Table
Four-Point Die Cushion in a Press Table with Adjustable Spindle Sleeves
Experimental Construction of a Simple Acting Hydraulic Press (10Point))
Force-Stroke Curves
A Hydraulic 4,000 kN Sheet Forming Press
Four-Point Die Cushion in the Press Table of a Simple Acting Press
Lower Drawing Frame (I))
Optimal Working Range for Deep Drawing
3705.06.01
Tool Materials
TALAT 3705
29
Figure No. Figure Title (Overhead)

3705.06.02 Surface Treatment Processes
3705.07.01
3705.07.02
3705.07.03
3705.07.04
TALAT 3705
CAD Illustration of a Coup Door Planking

Designing Surfaces
CAD Illustration of Edge "B" of the Drawing Punch Surface
Considering Springback in the Design
30

Drawing of Automotive Sheet Metal Parts: TALAT Lecture 3705

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Drawing of Automotive Sheet Metal Parts: TALAT Lecture 3705

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TALAT Lecture 3705

Drawing of Automotive Sheet Metal Parts

Date of Issue: 1996

3705 Drawing of Automotive Sheet Metal Parts

Forecast for the Year 2000

Forecast for the Year 2000

Training in Aluminium Application Technologies

3705.02 Characteristic Materials Parameters

Influence of Cold Work and Simulated

6009-T4 after stoving

Yield strength Rp0,2

Source: IFU Stuttgart

Influence of Cold Work and Simulated

Effect of r-Value on Yield Locus

Training in Aluminium Application Technologies

Elongation Values for AlMgSi1-ka

Elongation Values for AlMgSi1-ka in Polar Coordinates

Training in Aluminium Application Technologies

Vertical Anisotropy r for AlMg5Mn w

r value for g = 0.11

Vertical Anisotropy r for AlMg5Mn w

3705.03 The Drawing Process

Gripping jaws (clamps)

' Two-sided clamping

Stretching forming punch

Training in Aluminium Application Technologies

Stretch Forming a Bulge with a Spherical Punch

Source: IFU Stuttgart

Strain-Path Curves for Mechanical Drawing

Tear depth 36.5 mm

Strain-Path Curves for Mechanical Drawing

Hydraulic Stretch Forming

- Clamping force FK prevents flowing-in of sheet

Training in Aluminium Application Technologies

Strain-Path Curves for Hydraulic Drawing

Tear depth 36.5 mm

Strain-Path Curves for Hydraulic Drawing

Training in Aluminium Application Technologies

Comparison of the Principal Strains g

Comparison of the Principal Strains g

Deep Drawing with a Hemispherical Punch

- blankholder force FN prevents

- Forming zone is the sheet area between

Coefficients of friction should be kept small

Source: IFU Stuttgart

Deep Drawing with a Hemispherical Punch

Deep Drawing and Stretch Forming

Deep drawing and stretch forming

Deep Drawing and Stretch Forming

Drawing Irregular Sheet Shapes of Large Areas

Drawing Irregular Sheet Shapes of Large Areas

Drawing Irregular Sheet Shapes of Large Areas

Training in Aluminium Application Technologies

3705.04 Possibilities of Controlling the Material Flow

Control of material flow

Source: IFU Stuttgart

Control of Material Flow Under Blankholder

Arrangement of Draw Beads

Arrangement of draw beads

Source: IfU Stuttgart

Arrangement of Draw Beads

3705.05 Adjusting the Die Cushion

Mechanical vs. Hydraulic Press Equipment