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Printed in Great Britain. Pergamon Press Ltd.
S. K. GHosH
Department of Engineering, University of Cambridge, Cambridge, England
INTRODUCTION
Mechanical defects and limitations arising from various metal forming processes have
only recently tended to draw attention from academic workers. Several particular
journals devoted to manufacturing technology are increasingly reporting such topics
as defect formation, their causes and possible remedies. To-date, however, but few of
the many defects which occur are treated by researchers in terms of mechanics. The
Int. J. Mech. Sci. for example, has published during the past two decades a number of
papers relating to both practical studies on metal forming defects and their mathema-
tical modelling. The various defects reported are due to necking, the instability and
fracture of metals [1.1], wrinkling and buckling[1.2], springback [1.3], void or cavity
formation[1.4] and surface and structural damage [1.5].
The subject of defects may be divided for practical purposes into four main
categories as follows:
(i) those which arise in the stock material itself due to seggregation, pipe, porosity,
cracks and inclusions and exemplify harmful and undesirable defects of metallurgical
origin;
(ii) those which are introduced by incorrect heat-treatment such as overheating
and burning, rapid and uneven heating, over- and partial-hardening and annealing of
both blanks or preforms and the finished products;
(iii) those which result from improper mechanical action such as overworking
(overloading), wrong product layout, faulty tool design and finish and inadequate
lubrication; and
(iv) those due to elastic springback and generated residual stresses.
Table 1, most of which is reproduced from Ref. [2], lists the major defects that
arise in both bulk and sheet metal forming operations, whilst Table 2 presents a
separate list of some surface defects that are encountered in either one particular
process or a number of them. Readers are referred to the work of Johnson and
Mamalis [3] for an extensive list of references to the above lists of defects. Additional
references may be had from the general books on metal forming by Avitzur[4],
Boulger et al.[5,6], Blazynski[7], Roberts[8], Dieter[9], Koistinen and Wang[10],
Schey[11], American Society for Metals [12] and United States Steel Corporation[13],
and the recent papers reporting exclusively on various process defects by Lugosi and
Male[14], Miki et al.[15], Molytor[16] and Fujita et al. [17].
The author is presently engaged in classifying the principal and most common
defects encountered in both bulk and sheet metal forming operations and therefore
presents here a short note on the range of defects on the latter topic, that were
195
196 S. K. GHOSH
TABLE 1. THE COMMON PRINCIPAL DEFECTS ASSOCIATED WITH VARIOUS METAL FORMING PRO-
CESSES
Open- and Closed-Die Forging, DRAWING OF ROD, SHEET, WIRE AND TUBE
U~setting, Indentation
Internal bursts (cup and
Longitudinal cracking cone chevron)
Hot tears and tears Transverse surface cracking
Edge cracking Chips of metal
Central cavity Poor surface finish
Centre bursts Folding and buckling
Cracks due to t.v.ds and Fins, laps
thermal cracks Chatter (vibration) marks
Folds, laps Season cracking
Flash, fins Island-like welding
Laminations
Orange peel
Shearing fracture
Piping
DEEP-DRAWING
Wrinkling
Puckering
Tearing (necking)
Edge cracking
Orange peel
Stretcher-strains (L~ders
lines)
Earing
Cracking
WriDkling
Springback
HOLE FLANGING
Lip formation
Petal formation
Plug formation
Sheet metal forming defects 197
TABLE 1. (CONTD.)
Springback
Wall-fracture (shear splitting
and circumferential
splitting)
Wrinkling
Buckling
Back-extrusion (over-
reduction)
Under-reduction
Overlapping dimples
Orange peel
Surface tearing
Break-up of surface grains
Intergranular cracking
Wrinkling
Microfissures
Folds
r e p o r t e d a n d d i s c u s s e d b y r e s e a r c h e r s f r o m a n u m b e r o f c o u n t r i e s in t h e E l e v e n t h
Biennial Congress of the International Deep Drawing Research Group (IDDRG).
DEFECTS
The mechanical defects which arise during various sheet forming processes as described in this
conference range from such common principal defects as springback, wrinkling, buckling, necking and
fracture and surface marks to ones of specialized nature such as intergranular cavitation and'void
formation, shape fixabilityt defects in large panels, decohesion and Iocalised shear-band formation. These
defects are briefly reviewed below and interested readers may consult the referenced articles for further
details.
tFor shallow autobody parts possessing a surface of small curvature, e.g. a roof, door, hood or bootlid
panels, the important industrial criterion of acceptability is the accuracy of the shape. This property is
called "shape fixability" or "shape fittability" in Japan. Shape inaccuracy occurs due mainly to buckling,
wrinkling, surface warp, surface deflection or the springback of sheet after forming.
Springback
This topic was treated in papers or references [18.3, .5-.7, .28, .36, .43]. Reference [18.5] reports on the
correlation between material properties and the defects which appear when press-forming high strength
steel sheets. Fig, 1 [18.6] presents some press-forming results and the location of defects obtained as a result
of the deep-pressing of panels for automotive application; wrinkling, the waviness of panels and fracture is
also reported in this work. Restriking (a method of correcting or compensating for springback carried out
by "bottoming" the punch in the die so as to produce a coining action) components is shown to lower
substantially the magnitude of springback. Reference[18.28] presents curves for springback vs blank-
holding force in stretch-bending tests. As shown in Fig. 2(a), springback reduces with increasing blank-
holder force and the former is smaller for dual phase steel than that of high strength sheets. Figure 2(b)
shows the relationship between yield strength and springback for a shallow square shell from which it is
clear that the latter reduces with decreasing yield strength. Reference [18.36] also gives some springback
results, see Fig. 3(b), in connection with the forming of a square pan with a flat bottom, see also Fig. 3(a). It
was reported that this latter elastic recovery follows the strain path as did the strains during loading but in
the reverse direction.
Wrinkling and buckling
The author of Ref. [18.31] gives results for the number of wrinkles experimentally measured in the
deep-drawing of cylindrical shells of AI-killed cold-rolled drawing quality steel and compares them with the
number predicted by Kawai's wrinkling criterion,t see Fig. 4. (According to this criterion, the number of
wrinkles (N) is given by the following equation,
N = 1.81 ~rm2(4~ - b2)
where b is the width and r,. is the mean radius of the flange at the onset of wrinkling.)
Part n a m e
Hood-
ledge
upper
Wrinkle Springback
R o o f rail
outer
Springback
R o o f rail
inner
w.v r
Dash
side
~ract u111
Cro ss-
member
r~ure
FIG. 1. Press-forming results of shallow automotive panels[18.6] (material: high strength steel
sheet).
300 0 u
/
0.08
0.06 ~ 5
<1 0.4 Z~8/O=I- p/p
/
0.04 <1
g
g o2 F ,'/'
o. J ~¢ ~ Rephol.
U) 0.02
O I I I
0 i.O 2.0 3.0 o k ~ . - - & -~" , , , ,
I x..x,,(2oo ~oo 4oo
Blank holding force K N L X'X fX Yield strength MPa
(a) (b)
FIG. 2. Showing (a) the effects of blank-holding force on springback in stretch-bending test
and (b) the effect of yield strength on springback; re--punch corner radius in mm and
rp--punch profile radius (=50mm)[18.28] (HSLA and Steel 5: high strength low alloy steel,
Rephos. and Dual phase: rephosphorised AL-killed and dual phase steel).
Reference [18.30] presents a mathematical model for deep-drawing including the proneness to wrinkling
and compares the calculated number of body and flange wrinkles with those experimentally observed in the
drawing of conical shells. Reference [18.32] presents a schematic representation of the drawing force vs
blank diameter relation pertaining to the avoidance of buckling defects. A simple method was also
presented in the latter paper, following the above model, for evaluating the drawing force at the limiting
drawing ratio in the drawing of cylindrical cups with a flat-nosed punch. Wrinkling and loose metal obtained
in press-forming autobody panels is also reported in detail in Ref. [18.24].
Surface defects
Relating to the shape fixability or shape fittability[18.6, .7, .24, .27, .28] of large panels possessing
complex contours, such geometrical surface defects as surface warp [ 18.7, .24], wrinkling [ 18.24] and surface
deflection[18.5-.7, .24] were extensively discussed. These defects are attributed to non-uniform stress
distribution in the plane of the sheet; in addition, the inherent difficulties encountered in bending a sheet of
metal under tension, were pointed to as major factors giving rise to "shape fixing" defects.
(xI }
30 Sheet steel V
Ob
.c
lo
o
o
S 20 y~Y Springbaek
o ,o ~Sheet stee,l~"
c 30
o P ,,~/I
E
i- 20
0
o
I0
g
tlJ
A B = A B ' . D E = 130ram
BC=B'C=IIO
A D = 180 Equivalent strain after loading (~t)
(al (bl
FIG. 3. (a) Strain measured positions denoted by A to E and (b) elastic recovery in the
forming of square pan with flat bottom [18.36].
200 S. K. GHOSH
30 f ! I
> = O.98mm
o 3 . 0 8 mm
JO
o I I 1
I0 1.5 2.0 2.5 3.0
External surface defects have not previously been treated extensively apart from the occasional
mention of stretcher-strain marks[18.21]. Notable is the difference between the punch load-displacement
diagrams of sheets having the same composition but having been subjected to different heat treatment, see
Fig. 13 of Ref. [18,19].
Shear bands
References[18.20] and [18.26] give interesting observations regarding the formation of shear bands, see
Fig. 6, and coarse deformation bands. These bands are reported to be found at above a critical strain and to
be responsible for the discontinuity in work-hardening rate usually observed in the stretch-forming of
A1-Zn-Mg alloys, see the list of references given in Ref. [18.20]. Increasing Mn and decreasing Si content in
dual phase steels is said to produce a product with an increasingly banded distribution as shown in Fig. 6;
the latter may have some adverse effect on the formability of the type of steel sheet.
MeasUring ran •
~ n '' g Material:
_ ~ ~ High tensile strength
Steel (440 MPa)
~.,~l l l l l l l l llf
"---- Unloaded
(b),. --
dl
(e)
pa
l 47 2 ,
to/~o-looo
,""'~.. \
Dc
0.98
"'-'-,,5
°°a \i
\ /
0.96
(c)
FIG. 9. (a) Scanning electron micrograph observation in the plane (~1e3) of the initial damage
in an AI-kiiled steel; rolling direction (RD): 1, thickness direction: 3, (b) scanning electron
micrograph in the plane (e~3) of the damage in an Al-killed steel deformed by equibiaxial
deformation up to 2~1 = 2~2 = 0.8, and (c) critical defect (De) vs reduced hydrostatic pressure
(p') for different ratios of the initial thickness (to) to the initial radius of the cavities (ro) for an
Al-killed steel (p = ~/~2 = 1 i.e. balanced biaxial stretching)[18.13].
204 S.K. GHOSB
0.4
0.2
-0.2
~y
-0.4
-0.6
-o.e
-I,0
(a)
0.08 O. 0 8 None
....... . . . . . . . . . o. 16 0.16
O. 2 I 0.21 Occured
I
O. 2 5 O. 25 '=
O. I0 - O. I 3 None
O, 2 2 - O. 2 4 "
. . . . . . . . C ¸- -~.......
O. 2 8 - O. 3 2 "
,L=
O. 3 3 - O. 4 4 "
(b)
FIG. 10. (a)Flakinglimit strain diagram for hot dip galvanized steelsheet, and(b)observedsurface
layers after the forming of hot dip galvanized steel sheet; ~x and ~y are minor and major principal
strains, respectively [ 18.16].
Sheet metal forming defects 205
FIG. 11. (a) Progressive development of necks, in 18Cr-8Ni cladding, with increasing re-
rolling reductions in the range 30-70%, and (b) failure of heavily cold reduced laminate
associated with necking grooves in steel cladding[18.41].
urltace
urf~
FIG. 12. Strain fields observed on "FIAT 127 Sport" wheel disc; the hatched area indicates
the strain field which caused localized necking[18.29] (et--major strain, e2--minor strain).
206 S.K. GHOSH
,30#m
x I0 ~
,.o~,.-i-~T ¢_ Ko
I l I I I
0 0.1 0.3 0,5
(c)
FIG. 13. Double mechanism of crack formation: (a) by failure of the particle a n d (b) by
decohesion at the particle-matrix interface. (c) Number of defects per unit area (D) observed
vs effective strain (g) in stretching of two low-carbon steel sheets where e2/e; = p [18.11].
Sheet metal forming defects 207
d
FIG. 14. Post-formed brittle fractures in sheet steel parts: (a) industrial lamp housing in
deep-drawing cold-rolled steel; (b) laboratory deep-drawn cup; (c) mine roof-bolt header plate;
and (d) automotive bumper. (b)-(d) High strength low alloy hot-rolled steel[18.10].
S. K. GHOSH 209
TABLE 2. SURFACEDEFECTSTHATARISEIN BOTHBULKANDSHEETMETALFORMINGPROCESSES
Coating defects
The principal defect encountered in the deep-drawing and stretch-forming of coated sheets has been
recognised to be the flaking or peeling off of the coat material. Flaking limit strain diagrams, see Fig. 10(a),
have been plotted and cross-sections of coat-material after forming are shown in Fig. 10(b); see Ref. [18.16].
Additionally, in forming coated sheets, especially into box-shaped panels, there is the possibility of a loss of
coat-material at the corners[18.25]. Reference [18.39] suggests a testing procedure to evaluate the ad-
herence properties of coatings.
Acknowledgements--The author is indebted to Prof. W. Johnson for initially directing his attention to the
study of defects in metal processing and for his advice and help in completing this manuscript. He would
also like to thank Rosalie Cowell for typing the manuscript.
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210 Sheet metal forming defects
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sheet for autobody panels, p. 257.
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after cold forming in HSLA steel sheets, p. 281.
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18.12 P. F. THOMSON and P. U. NAYAK, The development of thickness non-uniformities leading to
failure in sheet metals, p. 303.
18.13 J. M. JALINIER,J. H. SCHMITT,R. ARGEMI,J. L. SALSMANNand B. BAUDELET,Different damage
behaviours and their influence on forming process, p. 313.
18.14 L. FELGI~RES,Calculation of the damage behaviour during stretch forming. Case of a cylindrical
multipasses deep drawn box, p. 327.
18.15 CIq. WEIDEMANN,Deep drawing of coil coated steel sheet, p. 343.
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treated steel sheet, p. 353.
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moderately elevated temperatures, p. 413.
S. K. GHosn 211
18.24 K. YOSHIDA, K. MIYAUCHI,H. HAYASHI,H. ISHIGAKIand T. FURUBAYASHI,Fittability of metal
sheets in sheet metal forming, p. 423.
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18.26 T. R. THOMSONand R. M. HOBBS, Dual Phase steels. Production and formability, p. 455.
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