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Abstract: The aim of this paper is to review the state⁃of⁃the⁃art SFPs and their applications, and to provide a
guide for researchers and engineers working in this field. Various SFPs are classified according to the
combination ways of stamping and forging operations. The process principle of each combination is reviewed,
with its applications discussed. The state⁃of⁃the⁃art of SFPs suggests that future work in this field should focus
on the development of high⁃strength die materials, better lubrication control methods, forming machines with
intelligent control capacity and special functions, and some new SFPs for high strength or ultra⁃high strength
materials.
Keywords: sheet metal; stamping; forging; stamping⁃forging process
CLC number: TG306 Document code: A Article ID: 1005⁃9113(2017)03⁃0001⁃16
Received 2017-01-15.
Sponsored by the National Natural Science Foundation of China ( Grant Nos.50705034, 51175202, 51435007 and 51675201) .
∗Corresponding author. E-mail: wangxy_hust@ hust.edu.cn.
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Journal of Harbin Institute of Technology ( New Series) , Vol.24, No.3, 2017
introduced SFPs according to part cross⁃sections. In researchers working on metal forming, in this paper,
recent years, many new SFPs were developed. SFPs are classified according to the combination way of
Generally, a specific combination of stamping and stamping and forging operations, as shown in Table 1.
forging operations can make parts with specific features. Each class and related process principle are discussed
For a better understanding and to provide a guide for in details in the following sections.
Table 1 Classification of SFPs according to combination way
Method Operations Range of application
Drawing / flanging + upsetting Parts with thickened walls, or with outer teeth
Drawing + reverse flatting Tailored sheet, cups with thickened bottom corner, cups with thickened bottom
Bending + compression Tailored sheet, ups with thickened bottom corner
Combined forming method Drawing + extrusion / ironing Parts with thinned wall, step⁃shaped wall or wall having functional elements
Drawing + backward extrusion Parts with bossing, or thin walls
Blanking + forging Parts with local bulk forming
Extrusion Parts with bossing
Sheet forging method Spinning Asymmetrical parts with inner teeth or ribs
Joining Tubes connection, sheet connection
wall thickness or form functional elements.
3 Combined Forming Method This process has the widest application in
manufacturing parts with thickened walls. Wang,
3.1 Combination of Drawing / Flanging with et al. [6] and Luo et al. [7] thickened the outer wall of a
Upsetting pan to form a flywheel panel used in cars. As shown in
Parts with thickened walls or functional elements Fig.1, the sheet was drawn into the die by an inner
on the wall can be fabricated by the combination of punch, and then the wall was compressed axially to be
drawing / flanging with upsetting. In this combination, a thickened. Finally, the wall was thickened from 10 mm
vertical wall is firstly formed by drawing or flanging, to 11 mm.
and then an upsetting operation is taken to increase the
Fig.4 Forming process of a double⁃cup part with thickened inner wall [13]
Fig.5 Forming of gear [14] ,tool active elements and main processes
According to studies mentioned above, the press is required when taking in one step. However,
combination of drawing / flanging and upsetting can be the wall tends to buckle, which easily leads to folding.
taken in sequence or one step. Conventional hydraulic Hence, the thickening ratio in a single step is limited.
presses or mechanical presses can be employed for the To obtain greater thickness, a multi⁃stage thickening
process when taking in sequence, but a multi⁃action process should be employed. Thus, the combined
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Journal of Harbin Institute of Technology ( New Series) , Vol.24, No.3, 2017
process conducting in sequence is a better choice when used for manufacturing tailored parts and bottom
the thickening ratio is larger. If combining stamping thickened parts.
and thickening in one step, the die set is complicated 3.2.1 To form tailored parts
and a multi⁃action press is required. Due to the friction The combination of drawing with flatting is most
resistance, the difficulty of material flow increases with widely used for making tailored blanks which are used
the wall height, resulting in a small allowable wall to make parts with thickened corners.
height. Furthermore, the combination of drawing / Zhao et al. [15] developed a drawing⁃pressing
flanging with upsetting can not be used for parts with forming process to thicken the central area of a round
thickened portions not in the wall, such as tailored sheet metal. As shown in Fig.6, in the first step, the
blanks and parts with thickened bottom, since the load central portion of the round blank was drawn into the
cannot be directly applied to the plate. die. In the second step, the out rim of the workpiece
3.2 Combination of Drawing with Reverse was restrained, while the center portion was flatted and
Flatting thickened by a reverse compression. Tan et al. [16]
In this combination, the blank is firstly drawn to developed a two⁃stage forming process to manufacture
form a cup or a groove, and then the cup or groove is tailored blanks. In the first stage, the target portion of
flatted with the other portion clamped by a flat punch. the blank was drawn into a die. In the second stage,
The punch vertically compresses the blank to plane, the target portion was reversely compressed by a flat
while the punch force is changed to an in⁃plane force to die with a flange clamped to increase the thickness, as
compress the target portion. Via compression, the shown in Fig.7.
target portion was thickened. This combination can be
Fig.7 Two⁃stage forming process of tailor parts with local thickening [16]
Since the thickness reduction of the drawn part clamped between the blank holder and the die, the
corner leads to a poor mechanical property, some conical bottom was compressed into a flat one by both
engineers have to make tailor blanks with annular the counter punch and inner punch, resulting in
thickened zones as preforms to increase the corner increased thicknesses around the bottom and flange
thickness. Abe et al. [17] developed a three⁃stage corners. Finally, the flange corners and wall
stamping process including bottom thickening and thicknesses around the bottom were increased by about
corner flanging for a cup with a flange.In the first and 10%, as shown in Fig.8.
second stages, the cup with a conical bottom was In these processes, the drawing depth is the key
formed by drawing using conical punches, and the factor for thickening. If the drawing depth is too large,
volume of the conical bottom was larger than that of the the thickness increase of the center portion becomes
flat bottom. In the third stage, with the flange being un⁃uniform or the blank folds in the reverse
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Journal of Harbin Institute of Technology ( New Series) , Vol.24, No.3, 2017
compression step. Otherwise, the thickening ratio is not achieved by presses with translational movements, such
large enough. Thus, multiple steps are required to as hydraulic presses and mechanical presses.
ensure the thickening ratio. This process can be
3.2.2 To form bottom thickened parts was squeezed into the bottom during drawing. After
The combination of drawing and compression can that, the bottom was compressed and thickened from
also be used to make parts with thickened bottom. Jin 4 mm to 4.25 mm.
et al. [18] manufactured aluminum alloy shell parts with In this process, the initial interposition of counter
non⁃uniform thickness by using a single⁃step hot punch is the key factor for bottom thickening. An over⁃
stamping forging process. In this process, a die⁃set large initial interposition results in a small thickening
with floating seat was employed.As shown in Fig.9, the ratio, otherwise, a non⁃uniform bottom will be formed.
die was installed in a stationary seat and fixed together. The merit of this process is that both drawing and
The counter punch was installed on a spring⁃supported flatting are achieved in only one step, and the
floating seat. In the beginning, the blank was placed shortcoming is that the volume of material squeezed
on the top of the die. Then, the punch descended to into the bottom from the wall is difficult, resulting in a
deform the workpiece, and the workpiece pushed the high forming load and small thickening ratio of the
counter punch downward. In this process, a convex bottom.
bottom was firstly formed, and the material in the wall
Fig.9 Forming process of a pan with thin wall and thickened bottom [18]
compression similar to that in drawing⁃reverse described in section 3.2, in this process, the thickened
compression processes. Comparing to the process zone is straight as the blank is bent along a line.
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Journal of Harbin Institute of Technology ( New Series) , Vol.24, No.3, 2017
Mori et al. [23] developed a hot forming process for to form the teeth ( see Fig. 16 ( c ) ) . To realize the
gear drum from an ultra⁃high strength steel. The sequence of heating, releasing and forming, an 800 kN
sequence of this novel spline forming process was CNC servo press was synchronized with the power
illustrated in Fig.16. In Fig.16( a) , the cup wall was supply for heating and air cylinders for the electrodes
electrified to heat between the upper and lower while moving. The difficulty of this process for
electrodes. And then, the two electrodes were moved manufacturing gears was controlling the material to full
away by air cylinders, as shown in Fig. 16 ( b ) . fill the tooth top.
Finally, the cup was drawn through the die by a punch
Drawing can also be combined with backward solid bosses from a plate. Fig.17( a) shows the process
extrusion. Wang et al. [24] proposed a new combined principle. When the die was moving upward, and the
process of drawing and compression to form a cup with blank was drawing, a constant punch load was applied
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Journal of Harbin Institute of Technology ( New Series) , Vol.24, No.3, 2017
to the bottom. Thus, a boss was extruded in the bottom temperature, and then the preforms were hot extruded
when the plate was compressed. to the desired geometry, as shown in Fig.18.
In order to investigate the influence of the boss Lin et al. [26] formed hollow parts having flange
position on the boss forming behavior, a double⁃boss from sheet metals by combining drawing and cold
model ( as shown in Fig. ( 17c ) ) was studied. The extrusion. As shown in Fig. 19 ( a ) , firstly, a cup⁃
distance from the boss center to the cup center changed shaped workpiece with a center hole was formed by
in the range of 3 - 13 mm. Figs. 17 ( d ) and ( e ) drawing. Secondly, it was put into the die cavity. The
compare the cross sections of the cup obtained by punch and the moveable die extruded the rim of the
simulation and experiment. The experimental result workpiece together to form a flange in the center of the
shows a good agreement with that of the simulation. cup bottom at the back face. During this process, the
Sheng et al. [25] proposed a hybrid forming process cup was positioned by the cup holder and the movable
by combining the warm drawing and hot extrusion to die. The formed workpieces were shown in Figs.19( b)
produce cup parts with inner ribs.In which a sheet was and ( c) .
firstly drawn to form a preform at warm forming
The combination of drawing with ironing / forward the bottom can make the material in the bottom flows
extrusion is favorable for making thinned wall parts or outward, resulting in a lower flow stress. Thus, the
gears. The key factor of this combination is the forming load is decreased. Meanwhile, a thicker blank
entrance shoulder angle of the die. An excessively low is required for compensating the material flow to the
angle will lead a large deformation zoom, resulting in a wall from the bottom. Compared to the conventional
serious friction force. Furthermore, the angle is limited hole flanging, the advantage of making hollow flanged
to the step shape of the part wall in some cases. A too parts by this process is that the forming limit is much
large angle will make the material flow difficultly. As higher.
the wall mainly deforms in tension when forming gears, 3.5 Combination of Blanking with Forging
the material is difficult to fill the tooth tip. The merit of Some stamping processes can also be combined
drawing combined with backward extrusion for forming with die forging processes. Hui et al. [27] combined a
cups with solid bosses is that the radial tensile force in blanking process with a closed⁃die forging to
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Journal of Harbin Institute of Technology ( New Series) , Vol.24, No.3, 2017
manufacture an aviation connector, as shown in Fig.20. portion of the workpiece together with a lower punch
Firstly, the main shape of the part was made by fine having a conical end to make the material flow into the
blanking, and then the branches were bent, finally, corner. In the second step, a lower punch with
the small boss was formed by a closed⁃die forging. Li et chamfered end was used instead of the conical one,
al. [28] developed a process by combining drawing with with the compression of the two punches, more
closed⁃die forging to form an automobile clutch bush. materials were driven to the corner. Thus the corner
In the first step, the preformed blank was drawn into was thickened, as shown in Fig.21.
the cavity die by a flat punch. When the up punch In these processes, as the stress is very high in
reached a certain depth, it compressed the center closed⁃die forging, the forging area is generally small.
Extrusion can also make bosses in both sides of a extrusion to manufacture a load⁃bearing disk, as shown
sheet, and if the section change is large, multi⁃step is in Fig.26.
required. Cai et al. [34] developed a multiple step
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Journal of Harbin Institute of Technology ( New Series) , Vol.24, No.3, 2017
Fig.23 Press⁃forged cases at different punch strokes [30] In plate extrusion, as the punch pressing the
blank in the plane, the contacted area is large. Hence,
it is hard for the material to flow and the material
between the punch and die suffers from high hydrostatic
pressures, resulting in a very large punch load. Thus,
the key issue of this process is to decrease the punch
load and promote the material flowing to the boss. For
this purpose, Maeno et al. [35] applied load pulsation
into the forging of a stainless steel sheet to form a boss
without cavity and rollover, as shown in Fig. 27. The
load pulsation can effectively improve the forming
Fig.24 Formed cooling fin [31] shape as well as decrease the forming load.
reducing friction, such as better lubrication, load result was also investigated. It was proved that the
pulsation, and tailored die surface, should be taken. groove angle played the dominant role. Jin et al. [39]
4.2 Spinning studied the metal flow in this process. The flow line
It is well known that spinning is a flexible revealed that the material was not only compressed in
incremental forming process suitable for asymmetrical the radial direction but also driven to flow in the
parts. The forming load is relatively low, since the tangent direction in the outer side of the rim.
workpiece deforms gradually under the partial tool In this process, as the rim is subjected to radial
contact. Conventionally, this process is used to form compression, it is easy to buckle, leading to a small
tabular parts or cup parts with thinned walls or wall thickening ratio. Multiple steps should be taken if a
thicknesses equal to those of original blanks. With the large thickening ratio is required. Moreover, the
development of this process, it can be used for buckling is sensitive to the roller shape. Thus, the
manufacturing parts with thickened walls or other roller shape should be optimized.
functional elements. 4.2.2 Spinning for teeth or rib
4.2.1 Spinning for rim thickening Cup parts with inner teeth are widely used in
For parts with thick rims and thin web plates, automobiles. Xu et al. [40] developed a multi⁃pass
Wang et al. [37-38] proposed a new rotary forming stagger spinning process to form a gear with internal
process, as shown in Fig.29. In the proposed process, teeth from plate blank. Two passes, i. e., power
a workpiece was sandwiched between the upper spindle spinning and drawing spinning, were designed for
and lower spindle, with all of them rotating together. A stagger spinning. It was shown that the using drawing
roller with an outside groove compressed the workpiece spinning in the first pass is helpful for teeth forming in
in the radial direction to thicken the rim. The forming the second pass, as shown in Fig.30. Xia et al. [41] and
process stopped when the roller contacted the spindle. Ma et al. [42] also employed this process to manufacture
In this study, the effect of groove shape on the forming clutch hubs with inner teeth.
Jiang et al. [43] manufactured a thinwalled tubular spinning ( Fig. 31 ( a ) ) . The experimental results
part with longitudinal inner ribs using backward ball showed that the minimum ball diameter should be
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Journal of Harbin Institute of Technology ( New Series) , Vol.24, No.3, 2017
controlled to guarantee the occurrence of inner ribs. mechanical property and is not economical due to the
The minimum diameter of the ball is decided by the low material utilization and long machining duration.
process parameters, i.e., the feed ratio, the reduction Meanwhile, spinning has advantages when dealing with
of wall thickness, the thickness of the blank and the this kind of parts.
material property. The experimental results indicated Ma et al. [44 - 45] formed conical parts with
that a larger ball size contributed more to the metal flow transverse inner ribs via a power spinning process. To
stability and the formability of the inner ribs, but too form the transverse rib and take off the workpiece from
large ball size resulted in poor surface quality. the die, a mandrel with splint was used, as shown in
Transverse inner rib of conical parts is generally Fig.32.
made by machining, but it will decrease the
Bragança et al. [53] developed a process to join passed entirely through the mortise. Then, compression
sheets perpendicular to one other, as shown in Fig.39. was applied on the end of the tenon to make plastic
In the process, one sheet had a rectangular hole deformation and ensure a mechanical lock between the
( mortise) cutout, and another one had a tenon cutout two sheets to be joined.
in the edge. The tenon was longer than mortise and
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