ScienceDirect

ScienceDirect
Procedia Manufacturing 36 (2017) 000–000
Available
Availableonline
Procedia atatwww.sciencedirect.com
online www.sciencedirect.com
Manufacturing 36 (2017) 000–000

ScienceDirect
ScienceDirect  www.elsevier.com/locate/procedia
www.elsevier.com/locate/procedia
Procedia Manufacturing 20 (2018) 141–146
Procedia Manufacturing 00 (2017) 000–000
www.elsevier.com/locate/procedia
2nd International Conference on Materials Manufacturing and Design Engineering
2nd International Conference on Materials Manufacturing and Design Engineering
Experimental Investigation on Forming Limit Diagram of Mild Carbon Steel
Experimental Investigation on Forming SheetLimit Diagram of Mild Carbon Steel
Manufacturing Engineering Society
Vishwajeet Sheet
International
R. Shinge 1
Conference
, Uday 2017,
A. Dabade 2
MESIC 2017, 28-30 June
1Department
2017, Vigo
of MechanicalVishwajeet
Engg. Nanasaheb(Pontevedra),
R. Shinge 1
, Uday
Mahadik A. Spain
CollegeDabade 2
of Engineering, Peth, Sangli, India.
1Department (vishwajeet1989@gmail.com)
of Mechanical Engg. Nanasaheb Mahadik College of Engineering, Peth, Sangli, India.
2Department of Mechanical Engg. Walchand College of Engineering, Sangli, India. (uadabade@gmail.com)
(vishwajeet1989@gmail.com)
Costing models for capacity optimization in Industry 4.0: Trade-off
2Department of Mechanical Engg. Walchand College of Engineering, Sangli, India. (uadabade@gmail.com)

Abstract between used capacity and operational efficiency

Abstract
The sheet metal forming process is the process of deforminga,* the sheet metal
The sheet metal
excessive localized forming
A. Variables
process
necking.
Santana a
, P. Afonso
is the process
in sheetofmetal
deforming
, A.
forming
Zanin
theprocess
b
sheet metal
R.into
,can into
a desired
Wernke b shape without fracture or
a desired together
be discussed shape without fracture or
with formability
excessive localized There
and test methods. necking.areVariables in sheet
manya University
defects metal
occurring forming
during process
sheet metal
of Minho, 4800-058 Guimarães, Portugalcan be discussed
forming together
processes, with
such asformability
cracking,
and test methods.
wrinkling, There are
local necking, many defects
buckling etc.
b Theoccurring
Unochapecó,strain during
measurement
89809-000 sheet
Chapecó, inmetal
SC, forming sheet
a deformed
Brazil processes,
metalsuch as cracking,
is necessary for
wrinkling,
measurement local necking, As
comparison. buckling etc. The
the thickness strainmetal
of sheet measurement
is very small in as a compare
deformedtosheet other metal is necessary
dimensions of the sheet for
measurement
metal, the sheet comparison. As theisthickness
metal operation of sheet metal
usually considered as a is verystress
plane smallproblem.
as compare ThetoForming
other dimensions
Limit Diagram of the(FLD)
sheet
was also
metal, thedetermined
sheet metalfrom surface
operation strain measurement.
is usually considered asThe FLDstress
a plane is theproblem.
graph between major Limit
The Forming strain Diagram
(℮1) and (FLD)minor
Abstract
was
strainalso determined
(℮2). The Forming from surface
Limit strain
Curvemeasurement.
(FLC) or the TheForming
FLD is the Limit graph between(FLD)
Diagram majorisstrain (℮1)concept
useful and minor for
strain (℮2). The
characterizing Forming Limit
the formability Curve
of sheet metal, (FLC)
whichorreflects
the Forming Limit principal
the maximum Diagram strains
(FLD)that is can
useful concept for
be sustained by
Under the concept
characterizing
sheet materials the
prior ofto"Industry
formability
the onset 4.0",
of sheet production
metal,
of localized which processes
reflects
necking. thewill be
maximum
Generally therepushed to bestrains
principal
are three increasingly
methods thattocan interconnected,
be sustained
establish FLD i.e. by
information
sheet materials
theoretical, based
numerical on atoreal
prior thetime
and onsetbasis and, necessarily,
of localized
experimental. necking.
In this papermuch more efficient.
Generally
experimental are Inthree
there method thisismethods
context,
used tocapacity
todevelop optimization
establish FLD For
FLD. i.e.
goes beyond the
theoretical,
experimental traditional
numerical
determination andaim of capacity
ofexperimental.
FLD of Mild maximization,
In papercontributing
this steel
Carbon Limit also
experimental
sheet Dome forHeight
organization’s
method istesting profitability
used isto develop
used accordingand
FLD. value.
to For
the
Indeed,
American lean
experimental management
determination
Society and
of TestingofMaterialcontinuous
FLD of(ASTM) improvement
Mild Carbon approaches
steel sheet
as published Limit Dome
in ASTM suggest
E 2218-02. capacity
HeightIn testing optimization
this paperis used instead
accordingoftogrid
the procedure of
the
maximization.
Americanpunch
marking, The
Society study of
of Testing
stretching capacity
andMaterial optimization and
(ASTM) as published
strain measurement costing
is used. For models
in ASTM is an important
E 2218-02.operation
punch stretching research
In this paper
the set topic that
theupprocedure deserves
of spherical of grid
die
contributions
marking,
and punchpunch from
has both theand
stretching
developed onpractical
strain
the and
hydraulic theoretical
measurementUniversalisperspectives.
used. Thisstretching
For Machine
Testing punch paper
(UTM). presents
The and
operation discusses
the
material set up aof
used mathematical
forspherical
the die anddie
model
punch for
and punch capacity
is Highhas Carbon management
developed High thebased
onChromium onSteel
hydraulic different
Universal costing
(HCHCr). Testing
Formodels (ABC
Machine
printing and
gridsTDABC).
the(UTM). onThe Amaterial
material
sheet generic model
for thehas
usedchemical diebeen
and
etching
developed
method and
punch isisHigh used.itCarbon
was used
In this to analyze
High
grid Chromium
making idle capacity
Steelgrids
process and
of to
(HCHCr). 5 design
mm strategies
Fordiameter
printing thetowards
circles grids thesheet
on
printed. maximization
For material of organization’s
chemical
trial experiment etching
the sheet
value.
method The trade-off
is used.
metal sample is In capacity
this
stretched maximization
gridat making
the force of 23vs
process operational
grids
KN. mm efficiency
of 5 deformed
The diameter is highlighted
circles
circles wereprinted.
convertedand it is ellipse
For into
trial shown and
experimentthat from
capacity
the sheet
that
metal
deformedsample
optimization ellipseis stretched
might major
hide and atminor
the force
operational strainsof are
23 to
inefficiency. KN.be The deformed
calculated. circles
After that the wereFLD converted
will giveintothe ellipse and from
two different that
regions
©deformed
of2017 andellipse
safe The failuremajor
Authors. zone. and minor
Published strains
by Elsevier B.V. are to be calculated. After that the FLD will give the two different regions
of safe andunder
Peer-review failure zone.
responsibility of the scientific committee of the Manufacturing Engineering Society International Conference
© 2017The Authors. Published by Elsevier B.V.
2017.
© 2018 The Authors.
Peer-review Published by Elsevier
under responsibility B.V.
© 2017The Authors. Published byofElsevier
the scientific
B.V. committee of the 2nd International Conference on Materials
Peer-review under responsibility of the scientific committee Idle
of the 2nd International Conference on Materials Manufacturing and
Manufacturing
Peer-review
Keywords: Cost under and
Models;
Design Engineering.
Design Engineering.
responsibility
ABC; TDABC; of the
Capacity scientific
Management; committee of the
Capacity; 2nd International
Operational Efficiency Conference on Materials
Manufacturing and Design Engineering.
Keywords: Forming Limit Diagram, Forming Limit Curve, Universal Testing Machine, and Limit Dome Height.
1. Introduction
Keywords: Forming Limit Diagram, Forming Limit Curve, Universal Testing Machine, and Limit Dome Height.

The cost of idle capacity is a fundamental information for companies and their management of extreme importance
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
2351-9789© 2017 The Authors. Published by Elsevier B.V.
in several ways:
Peer-review tons of production,
under responsibility available
of the scientific hours of
committee manufacturing,
of the etc.Conference
2nd International The management of Manufacturing
on Materials the idle capacity
and
2351-9789© 2017 The Authors. Published by Elsevier B.V.
* PauloEngineering.
Design Afonso.
Peer-review Tel.:
under +351 253 510 of
responsibility 761;
thefax: +351 253
scientific 604 741 of the 2nd International Conference on Materials Manufacturing and
committee
E-mail address:
Design Engineering.psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review
2351-9789 © under
2018responsibility
The Authors. of the scientificbycommittee
Published Elsevier of the Manufacturing Engineering Society International Conference 2017.
B.V.
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
Design Engineering.
10.1016/j.promfg.2018.02.020
142 Vishwajeet R. Shinge et al. / Procedia Manufacturing 20 (2018) 141–146
Vishwajeet R Shinge, Uday A Dabade/ Procedia Manufacturing 36 (2017) 000–000

1. Introduction

Sheet metal forming process is method of transforming sheet metal into required shape without fracture. In
recent years some numerical methods are used for modeling the sheet metal processes. However several finite-
element packages are also available for analysis of sheet metal forming processes. As each software gives different
results it is important to verify finite results with experimental results. Surface strain measurements are important in
case of sheet metal process due to thickness being very small as compared to other dimensions of sheet metal.
Forming Limit Diagram also determined by using Surface strain measurement. FLD’s can be constructed by using
experiments of hemispherical punch-stretch tests and Marciniak cup tests. These experimental methods require
intensive efforts and time. Some analytical methods are used to improve efficiency of FLDs. However failure cannot
be estimated by analytical methods. A forming limit diagram (FLD) is a graph which depicts the major strains (℮1)
for all values of the minor strain (℮2) at the onset of localized necking. However, because of scattering in the
measured necking strains, a narrow band is normally utilized for necking evaluation [1-2].

Fig. 1.1 Forming Limit Diagram [3].

FLD is shown in Fig. 1.1 which is divided into two regions separated by a curve, the forming limit curve
(FLC). The region below the FLC corresponds to safe strain states whereas that above the FLC represents failure
strain states. Even though the strain states of the sheet metal forming processes are complex, FLDs are often
constructed using tensile and biaxial stretch tests. As the use of FLD in sheet metal forming industry increases
different experimental methods were proposed. Among them ASTM standard test is mostly used. In this test
hemispherical punch is used to stretch material on which grids are printed. After stretching operation the grids
deformed. Using the deformation of these grids major and minor strains are calculated and graph between major and
minor strains is formed [3].

2. Literature Review

V Talyan et. al. [4] studied the formability of Ferritic and Austenitic stainless steel by using tensile Test
and Limiting Dome Height test. Result shows that Ferritic steel deform as same as Plain Carbon steel where as
Martensite is formed in Austenitic steel due to various strain rate and temperature.
T. Pepelnjak and K. Kuzman [5] has developed Forming Limit Diagram by using Marciniak testing
procedure simulated with the FEM program ABAQUS on Galvanized steel, Plain Carbon steel, Al-Alloys and Ti-
Alloys with different thickness. Result shows the corelation between experimental and numerical analysis.
Gleiton Luiz Damoulis et. al. [6] used the FLD for the analysis of different forming processes in industries.
Before tool production process simulation is the effective method. FLD is used as the method of designing tool for
the forming processes for different materials.
 Vishwajeet R. Shinge et al. / Procedia Manufacturing 20 (2018) 141–146 143
Vishwajeet R Shinge, Uday A Dabade / Procedia Manufacturing00 (2017) 000–000 3

Dahan [7] et. al. has explained the procedure for the experimental determination of a forming limit curve
for USIBOR 1500 P. USIBOR 1500 P is a coated C-Mn steel, micro-alloyed with boron, with excellent processing
properties in hot stamping, both in terms of formability, quenchability and surface protection, and leading to
superior mechanical properties on the formed part.
The Forming Limit Diagram is determined by Sahu [8] et. al. using Hecker’s simplified techniques on High
Strength steel sheet. FLD is developed for different sheet thickness. It shows that the Major strain various from 2.5
% to 8 % and Minor strain various from -1.25 % to -5 %. In many cases component fractures at a time of forming.
The causes of failure is the factors related to forming processes.
N. Sene [9] et. al. has developed micro-forming limit diagrams. In this paper two numerical simulation
based on the finite element method is used one is reduced numerical simulation and second is full tool experimental
method. Thin Aluminium sheet (0.2 mm) with a specific tool for small dimensions (9-mm punch) is used. Result
shows that reduced numerical simulation method reduces time for forming limit diagram.
M. H. Chen [10] et. al. has used application of forming limit diagram for the multistep forming processes
for automobile panels. The validation of the forming limit diagram is done by using FEM simulation. Result shows
that effective and efficient use of FLD can be done in multistep forming processes.

3. Experimental Procedure
3.1 Workpiece Material
Plain carbon steels are mainly used in automobile industries. Low carbon steel that is mild carbon steel
is selected as a work piece material. The mild steel is mainly used steel in sheet metal operations to form
automobile parts and many other appliances. The composition of Mild Carbon Steel sheet is shown in table 3.1.

Table 3.1 Composition of Mild Steel Sheet Sample in %

C Si Mn P S Cr Mo W
0.0520 0.0581 0.221 <0.0030 0.00443 0.0330 0.0361 0.0718
Ni Cu Al Co Nb Ti V Fe
0.0235 0.0108 0.104 0.123 0.00870 0.00326 0.00048 99.2

3.2 Setup for Experiment

For punch stress operation the set up has been developed on Universal Testing Machine. Fig. 3.1 shows the
setup for experiment on which hemispherical die and punch are mounted.

Fig. 3.1 Setup for punch Stretching Operation.

144 Vishwajeet R. Shinge et al. / Procedia Manufacturing 20 (2018) 141–146
Vishwajeet R Shinge, Uday A Dabade/ Procedia Manufacturing 36 (2017) 000–000

3.2.1 Selection of tool material

Proper material selection should be carried out to prepare die and punch. Grades D3, D4 and D7, contains
additional carbon, which increases wear resistance, however, the toughness is somewhat lower [11]. After preparing
the die and punch the hardening process is carried out. Here High Carbon High Chromium Steel is selected for tool.
The hardness of this material can be achieved up to 60 to 65 HRC. Composition of HCHCr material is shown in
table 3.2.
Table 3.2 Composition of HCHCr Sample in %
C Si Mn P S Cr Mo Ni
2.04 0.164 0.178 <0.0030 <0.0030 13.30 <0.0050 0.0499

Cu Al Co Nb Ti V Fe

0.0103 0.00798 <0.0050 <0.0100 0.0114 0.0280 84.2

3.3 Preparation of Work Sample

Before stretching the work sample on UTM the grids of circles of 5 mm diameter were prepared on sample
of dimension 200×200 which is shown in Fig. 3.2. The method used for printing the grids is the chemical etching
method.

Fig. 3.2 Grid Printed on Sample Sheet Material.

3.4 Punch Stretching

Fig. 3.3 Sheet Metal Samples Stretched at Different Loads.

 Vishwajeet R. Shinge et al. / Procedia Manufacturing 20 (2018) 141–146 145
Vishwajeet R Shinge, Uday A Dabade / Procedia Manufacturing00 (2017) 000–000 5

After printing the grids on work sample the stretching operation at different load of 10 KN, 12 KN, 14 KN,
16 KN, 18 KN, 20 KN, and 23 KN were performed on UTM using hemispherical punch and die. After punch
stretching operation the grids which were printed on sheet metal sample were deformed into the ellipse. Using these
ellipses the major and minor strains were calculated by measuring major and minor axis of ellipse in required
region. Fig. 3.3 shows the sheet samples stretched at different loads.

4. Experimental Results and Analysis

4.1 Measurement of Ellipse
After punch stretching operation the circle grids printed on sheet metal samples deformed into ellipse. For
developing FLD the major and minor strains calculated using formula:

The major axes and minor axes are measured using optical profile projector.

4.2 Plotting of Forming Limit diagram

The major and minor strains of all the ellipse of sheet metal samples stretched at different loads of 12 KN,
14 KN, 16 KN, 18 KN, 20 KN and 23 KN are calculated. For plotting the FLD we have selected the ellipse from
each sample having maximum major strain. Table 4.1 shows the maximum major strains of each sample.
Table 4.1 Maximum Major Strains at Different Loads

LOAD (KN) MINOR STRAIN (%) MAJOR STRAIN (%)

20 -12.14 32.82
14 -5.04 14.02
12 1.06 13.1
16 2.02 15.46
18 3.02 18.22
23 6.64 36.78

Fig. 4.1 Forming Limit Curve for 0.8 mm Thickness sheet.

 Vishwajeet R Shinge, Uday A Dabade/ Procedia Manufacturing 36 (2017) 000–000
146 Vishwajeet R. Shinge et al. / Procedia Manufacturing 20 (2018) 141–146

After selecting the maximum major strains the plot between major strain and minor strain has plotted as
shown in Fig. 4.1. Graph shows the forming limit curve in which there are two regions separated by curve. The area
above the curve is safe region and the area below the curve is failure region.

5. Conclusions

Based on the experiments performed for developing the FLD for Mild Carbon Steel sheet following
conclusions are drawn:
 The area below the lower line of the curve is the safe working zone for the sheet for all possible
combinations of strains.
 Above the upper line of the curve, the sheet metal is certain to fail by necking/fracture.
 The area within the curve represents the critical region where the sheet is likely to develop the
necking/onset of failure.
 Major strain varies from 13.1 % to 36.78 %. And minor strain varies from 1.06 % to 6.64 %.

References

[1] Fahrettin Ozturk, Murat Dilmec and Mevlut Turkoz, “Grid Marking and Measurement Methods for Sheet Metal Formability,” 5th
International Conference and Exhibition on Design and Production of MACHINES and DIES/MOLDS 18-21 JUNE 2009 Pine Bay Hotel -
Kusadasi, Aydin, TURKEY.
[2] Mahmoud Abbasi, Mohammad A. Shafaat and Mostafa Ketabchi, “Application of the GTN Model to Predict the Forming Limit Diagram of
IF- Steel,” Journal of Mechanical Science and Technology 26, 2012, pp. 345-352.
[3] ] Hyuk Jong Bong, Frederic Barlat and Myoung-Gyu Lee, “The Forming Limit Diagram of Ferritic Stainless Steel Sheets: Experiments and
Modeling,” International Journal of Mechanical Sciences 64, 2012, pp. 1-10.
[4] V. Talyan, R. H. Wagoner and J. E. Lee, “Formability of Stainless Steel,” Metallurgical and Materials Transaction, volume 29A , August
1998-2171.
[5] T. Pepelnjak, K. Kuzman, “Numerical Determination of the Forming Limit Diagram,” Journal of Achievement in Materials and
Manufacturing Engineering, volume 20, January-February 2007.
[6] Gleiton Luiz Damoulis, Edson Gomes and Gilmar Ferreira Batalha, “Analysis of the Industrial Sheet Metal Forming Process Using the
Forming Limit Diagram (FLD) through Computer Simulation as Integrated Tool in Car Body Development,” Laboratorio de Engenharia de
Fabricaçao - Escola Politecnica da Universidade de Sao Paulo, Brazil.
[7] Y. Dahan, Y. Chastel and P. Duroux, “Procedure for the Experimental Determination of Forming Limit Curve for USIBOR 1500P,”
International Deep-drawing Research Group IDDRG 2007 International Conference, 21-23 May 2007.
[8] Raj Kumar Sahu and Shrabani Majumdar, “Forming Limit Diagram of High Strength Steel Sheet (DP 590),” MIT International Journal of
Mechanical Engineering, Aug 2011, vol. 1.
[9] N. Sene, P. Balland, R. Arrieux, “Numerical Study of the Micro-Formability of Thin Metallic Materials: Virtual Micro-Forming Limit
Diagrams,” Archives of Civil And Mechanical Engineering, volume XI 2011.
[10] M.H. Chen, L. Gao, D.W. Zuo, M. Wang, “Application of the Forming Limit Stress Diagram to Forming Limit Prediction for the Multi-Step
Forming of Auto Panels,” Journal of Materials Processing Technology, 2007, pp.173–177.
[11] D. Smith, “Die Design Handbook,” Third Edition, Section 28, 1990.