Mise en Forme Par Déformation Plastique 1 Special Processes of Forming Technology

Mise en forme par déformation plastique 1
Special Processes of Forming Technology
MECA 2
Lecture 1: Introduction to the Technology of Metal

Forming
2019-20
Dr.-Ing. habil. Sami Chatti
Content of the Course
1 Introduction to the technology of metal forming
2 Spinning processes
3 Bar extrusion processes
4 Forming with working media and magnetic fields
2019 L01 Introduction 1.2
1
Structure
L1 – Introduction to the Technology of Metal Forming
Introduction
Classification of forming processes
Techno-economic aspects
Classification of Manufacturing Procedures

according to DIN 8580
Create Maintain Reduce Increase form

form form form
Form alteration
2. 3. 4.
Forming Cutting Joining
1. 6. 5.
Moulding Change of material properties Coating
Displacement Elimination Introduction

of material of material of material
particles particles particles
2
Manufacturing Possibilities of a Bolt
1. By casting 2. Partial upsetting or extrusion (forming)

( moulding )
Finished part
Small initial Large initial

cross-section cross-section
(material is pressed
through a nozzle)
3. By turning 4. By welding ( joining )

( cutting )
Waste
material
Structure
Introduction
3
Classification of Forming Procedures into
Subgroups according to DIN 8582
Forming
Tensile-
Compressive Tensile Bend Shear
compressive
forming forming forming forming
forming
Bending with straight
Bending with rotary
straight tool motion

Shear forming with
Flange forming
Stretch identing
Metal spinning
Deep drawing
Upset bulging
Free forming
Die forming
Indentation
tool motion
tool motion
Elongation
Expanding
Extrusion
Twisting
Drawing
Rolling
Compressive Forming:
Impression Die Forging
Initial state Instant state Final state
Upper die
Blank
Lower die
Workpiece
4
Compressive Forming - Forging
Example: Drop forging
www.volme-schmiede.de
Upper die
Workpiece
Lower die
Tensile-Compressive Forming: Deep Drawing

in the First Draw with Blank Holder
Punch
F
Blank holder FB FB
Blank
Die
10
5
Tensile-Compressive Forming –
Deep Drawing
Example: Deep drawing
www.volkswagen.de
Daimler
Punch
Blankholder
Sheet
Die
11
Tensile Forming: Expanding with Rubber

Punch
Punch
Rubber
Die
Workpiece
12
6
Bend Forming: Tube Folding
Clamping jaw
Bending roll
Bending die
Tube
13
Bend Forming: Tube Bending at OPEL
14
7
Shear Forming: Embossing of Sheet Metal
Components

Punch
FP
Blank holder
FBH
Sheet metal
Counter punch
Die
15
Dependence of the Maximum Formability on

the Medium State of Stress
Ca
pilg libra  Br
e tin  1 ->  2 ->  3
Ex
Ba r rolling roll
tru
Rno g, ing
dlw
 m = 1 ( 1 +  +  3 )
sio
lina for
glz m
1 >  2 =  3 2
n,
oefn for 3
gin
ba
s, hF g
r
elae
ex
ct hm
tru
set Ro
atab
sio
lw l lin
al g
n
ze wi
, fr
n th
ee
Lo
lo
ng
for
ng g (fo
i tu
mi
itu
di
n
n
din ging
al
te
al
1 =  2 >  3 ns
ro
r
io
llin
n
H
go
)o
iro ollo
fb
nf
ni w
ng se
loc
lat
ct
ks
su
io Dr
n
,u
rf a
dr aw
ps
aw in
ce
g
ett
in
s
g of
in
w wi
g
ith re
m
an
an Uniaxial
B d
te and el
dr ro
ds tension test
ns ro Ho
Uniaxial ion lli
ng wi lo l
wi t h w
compression test th o u se
t m ct
lon an ion
gi dr dr St
tu el aw re
din tch
al in -fo
g
rm
ing
Torsion test
-0.33 0 0.33
( according to H. Stenger ) m / k f
16
8
Classification of Forming Processes into Sheet
Metal Forming and Bulk Forming
Bulk forming Sheet metal forming
• Rolling / Profile rolling • Die bending / Folding

• Upsetting / Forging • Stretch drawing
• Bar extrusion • Deep drawing
 Many process variants have been developed

from the common methods
17
Definition of Metal Forming
Metal Forming:
Manufacturing of a product through a permanent change of the
shape, whereby the mass and the material connectivity do not
change.
Bulk forming: Sheet forming:

• Forming of components with • Forming of sheet
full and tubular cross sections components
• Intended change of cross • No intended change of
sections sheet thickness
• Usually hot forming • Usually cold forming
18
9
Bulk Forming vs. Sheet Metal Forming
Forming Processes
Bulk forming Sheet metal forming

F2 F1
F1 F2
F2
F3 F1
• Blank balanced in all three directions • Blank in the thickness direction
• Material flow in all directions much smaller
• Often multiaxial compressive stress • Workpiece: hollow body with
states approximately constant wall
• Greater forming forces than sheet thickness
metal forming
• Much older than sheet metal forming • Mostly biaxial stress states:
(forging, rolling) tension-tension or tension-
compression
19
Hot forming – Cold forming

According to DIN 8582
Forming after heating - Hot forming
Forming without heating - Cold forming
Forming without change in strength
Forming with temporary change

in strength
Forming with permanent change

in strength
20
10
Hot Sheet Metal Forming –
Press Hardening
Example: Press hardening Material: 22MnB5

Thickness: 1.75 mm
Oven temperature: 950°C
21
Motion States During the Forming Process
v Wz
Course line
Streamline v Wz
Motion state of a transient forming Motion state of a stationary forming

process (upsetting) process (bar extrusion)
22
11
Structure
Introduction
23
Material Savings by Cold Extrusion
Material: Ck 35
Quantity: 70 pieces/minute
(Hatebur) Material savings: 75%
24
12
Energy requirements in forming and machining
Component manufactured by forming Component manufactured by machining

50 50
Loss Loss
40 40
Energy requirement in MJ / kg
Energy requirement in MJ / kg
Forming Machining
30 30
Rolling Rolling
20 20
Steel manufacturing Steel manufacturing
10 10
0 0
 28 MJ / kg  45 MJ / kg
25
Comparison of Costs Forming - Turning
Formed workpiece
Material: Ma 8
Cost in Euro per 200 pieces
Ø20 Ø10 Turning
10 20
Forming
Turned workpiece
Material: 9 SMnPb 2 3
Ø20 Ø10
Number of parts x 1000
10 20
Example cold forming
In mm Workpiece weight Minimal number of workpieces:
<20 g 10.000
20 bis 500 g 5.000
500 g bis 10 kg 1.000
10 bis 50 kg 1.000
26
13
Fibre of a Drive Shaft After the Extrusion
Material: 41 Cr 4
Krupp
27
Fibre of Crankshaft
Forged crankshaft
Crankshaft manufactured by
„machining“
28
14
Reachable Accuracy in Forming
Assumption: diameter of the component (nominal dimension range) 120 to 180 mm
Specification of the tolerance range in mm
IT-Tolerance class IT05 IT06 IT07 IT08 IT09 IT10 IT11 IT12 IT13 IT14 IT15 IT16
Manufact. process Dimension 0,018 0,025 0,04 0,063 0,1 0,16 0,25 0,4 0,63 1,0 1,6 2,5
Hot forming Diameter
Cold forming Diameter
Turning Diameter
Milling Thickness
Cylindrical grinding Diameter
Normally reachable
Reachable by special measures
Accuracy of cold forming
Generally achievable Accuracy in the best Accuracy at best

Dimension
accuracy conditions future conditions
Inner diameter [mm] 0,06 0,01 0,005

Outer diameter [mm] 0,15 0,02 0,001
Thickness [mm] 0,3 0,1 0,05
Surface roughness Rmax [µm] 6 2 0,5
According to Kudo
29
Forming Technology and Lightweight

Construction in Transportation Systems
30
15
Appendix: English for Production Engineers
English Français English Français

Moulding/casting Moulage Compressive forming Formage par compression
Forming Formage Tensile forming Formage par traction
Cutting Usinage Bend forming Formage par cintrage
Joining Assemblage Shear forming Formage par cisaillement
Coating Revêtement Impression die forging Matriçage
Bolt Boulon Deep drawing Emboutissage profond
Upsetting Refoulement Sheet metal forming Formage de tôles
Welding Soudage Bulk forming Formage massif
31
16

Mise en Forme Par Déformation Plastique 1 Special Processes of Forming Technology

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Mise en Forme Par Déformation Plastique 1 Special Processes of Forming Technology

Uploaded by

Copyright:

Available Formats

Mise en forme par déformation plastique 1

Special Processes of Forming Technology

Lecture 1: Introduction to the Technology of Metal

Dr.-Ing. habil. Sami Chatti

Content of the Course

1 Introduction to the technology of metal forming

3 Bar extrusion processes

4 Forming with working media and magnetic fields

2019 L01 Introduction 1.2

L1 – Introduction to the Technology of Metal Forming

Classification of forming processes

2019 L01 Introduction 1.3

Classification of Manufacturing Procedures

Create Maintain Reduce Increase form

Displacement Elimination Introduction

2019 L01 Introduction 1.4

1. By casting 2. Partial upsetting or extrusion (forming)

Small initial Large initial

3. By turning 4. By welding ( joining )

2019 L01 Introduction 1.5

L1 – Introduction to the Technology of Metal Forming

Classification of forming processes

2019 L01 Introduction 1.6

Bending with straight

Bending with rotary

straight tool motion

2019 L01 Introduction 1.7

Initial state Instant state Final state

2019 L01 Introduction 1.8

Example: Drop forging

2019 L01 Introduction 1.9

Tensile-Compressive Forming: Deep Drawing

Initial state Instant state Final state

2019 L01 Introduction 1.10

Example: Deep drawing

2019 L01 Introduction 1.11

Tensile Forming: Expanding with Rubber

Initial state Instant state Final state

2019 L01 Introduction 1.12

Initial state Instant state Final state

2019 L01 Introduction 1.13

Bend Forming: Tube Bending at OPEL

2019 L01 Introduction 1.14

Initial state Instant state Final state

2019 L01 Introduction 1.15

Dependence of the Maximum Formability on

Bulk forming Sheet metal forming

• Rolling / Profile rolling • Die bending / Folding

 Many process variants have been developed

Definition of Metal Forming

Bulk forming: Sheet forming:

Bulk forming Sheet metal forming

2019 L01 Introduction 1.19

Hot forming – Cold forming

Forming after heating - Hot forming

Forming without heating - Cold forming

Forming without change in strength

Forming with temporary change

Forming with permanent change

2019 L01 Introduction 1.20

Example: Press hardening Material: 22MnB5

2019 L01 Introduction 1.21

Motion States During the Forming Process