ME 678

Mechanics of sheet metal forming

IIT GUWAHATI, GUWAHATI

July – November 2021

Lecture schedule:

• Monday, Tuesday, Wednesday : 9 to 9.55 am

Grading method: Following grading method (tentative) will be followed. We may

modify the weightage slightly at the end of the semester if required.

Assignments: 10%
Quizzes (online): 20%
Mid semester exam: 30%
End semester exam: 40%
 SYLLABUS
• Description of Material properties: Tensile test, effect of properties on forming.
• Sheet deformation processes: Uni-axial tension, general sheet forming processes, yielding, flow rule, work hardening
hypothesis, work of plastic deformation, isotropic and anisotropic yield functions, Bauschinger effect modeling, effective
stress and strain.
• Sheet deformation in plane stress: strain distributions, strain diagram, deformation modes, effective stress-strain laws,
principal tensions.
• Stamping analysis: 2-D and 3-D model of stamping, stretch and draw ratios in stamping.
• Load instability and tearing: uniaxial tension of perfect strip and imperfect strip, tensile instability in stretching continuous
sheet.
• Sheet formability: Forming limit curve – concept and evaluation, formability tests, theoretical prediction, factors affecting
FLC.
• Sheet bending: Variables in bending a continuous sheet, equilibrium conditions, material models, bending without
tension, springback.
• Analysis of circular shells: equilibrium equations, Models for forming axisymmetric shells.
• Cylindrical deep drawing: Drawing the flange, cup height, redrawing cylindrical cups, wall ironing of deep drawn cups.
• Stretching circular shells: Analysis of bulging with fluid pressure, stretching over punch.
• Combined bending and tension of sheet.
• Governing differential equations for finite element formulation.
• Recent advances: Hydroforming, tailor welded blanks, friction stir welding of sheets.
 Textbooks/References

[1] D. Banabic, Sheet metal forming processes Constitutive modeling and numerical
simulation, Springer-Verlag Berlin Heidelberg, 2010
[2] Z. Marciniak, J. L. Duncan, S. J. Hu, Mechanics of sheet metal forming, Elsevier,
Butterworth-Heinemann, 2002
[3] R. H. Wagoner, J. L. Chenot, Fundamentals of metal forming, John Wiley and Sons,
1997
[4] W. F. Hosford, R. M. Caddell, Metal forming Mechanics and Metallurgy, PrinticeHall,
2007
[5] J. Chakrabarty, Theory of Plasticity, McGraw Hill, 1998. [6] D. W. A. Rees, Basic
engineering plasticity, Elsevier, 2006
Problem 1

(a) A bar of length l0 is uniformly extended until its length l = 2 l0. Compute the values of the engineering and
true strains.
(b) To what final length must a bar of length l0 be compressed if the strains are the same (except sign) as in
part (a)?

Problem 2

A bar 10 cm long is elongated to 20 cm by rolling in three steps: 10 cm to 12 cm, 12 cm to 15 cm, and 15 cm to 20

cm.

(a) Calculate the engineering strain for each step and compare the sum of these with the overall engineering strain.
(b) Repeat for true strains.

Problem 3

Calculate the ratio of ε/e for e = 0.001, 0.01, 0.02, 0.05, 0.1, and 0.2.
Problem 4

The initial gauge length, width and thickness of a tensile test-piece are, 50, 12.5 and 0.80 mm respectively.
The initial yield load is 1.791 kN.
At a point, A, the load is 2.059 kN and the extension is 1.22 mm.
The maximum load is 2.94 kN and this occurs at an extension of 13.55 mm.
The test-piece fails at an extension of 22.69 mm.

Determine : initial cross-sectional area, initial yield stress, tensile strength, total elongation, true stress at
maximum load, maximum uniform strain, true stress at A, true strain at A, n