L8: Sheet metal

forming

Sheet Forming
 Sheet Forming as a SystemL8: Sheet metal
forming
The system variables affect the process and product quality

1. Workpiece / Blank 5. Equipment / Press

2. Tooling / Die Set 6. Part / Product
3. Tool/Mat’l Interface 7. Environment
4. Deformation Zone
 Classification of Sheet Metal forming
Processes L8: Sheet metal
forming

Blanking Hemming

Piercing Roll Forming

Trimming Stretch Forming

Bending Deep Drawing

Flanging
Sheet Formed Parts
L8: Sheet metal
forming
Failure in Sheet Metal Forming
L8: Sheet metal
forming

Issues
•Material
•Lubrication
•Process design
•Die design
Sheet Metal Characteristics
L8: Sheet metal
forming
• Elongation
• Yield Point Elongation
• Anisotropy
• Grain size
• Residual stresses
• Springback
• Wrinkling
• Fracture and Cracking
 Shearing Process with a Punch and Die
L8: Sheet metal
forming

Major variables
• Punch force
• Speed
• Lubrication
• Edge condition
• Material (punch& die)
• Corner radii
• Clearance btw die and punch
 Effect of clearance on shearing and
micro-hardness L8: Sheet metal
forming

C: Low C: High

Clearance ranges between 2%- 10% of the sheet thickness

 Shearing Load
L8: Sheet metal
forming

Approximate empirical formula for estimating the

maximum punch load is,

Pmax=0.7SutL

Su= Ultimate Tensile Strength

t = Sheet thickness
L = Total length shear( for a circular hole L=D)
D = Hole Diameter
 Sheet Cutting Operations
L8: Sheet metal
forming

Punching: The sheared slug is discarded

Blanking: The slug is the part and the
rest is discarded
 Progressive and Transfer Die
L8: Sheet metal
forming
Progressive Die:
• The sheet metal is fed through a
coil strip, and a different operation
is performed at the same station
with each stroke of a series of
punches

Transfer Die:
• The sheet metal undergoes
different operation at different
stations . After each operation, the
part is transferred to the next
station for addition operation
Progressive Die
 Minimum Bending Radius
L8: Sheet metal
forming
•Metal can only be bent so far
before cracks form at the bend
and, ultimately, the metal
breaks

R: minimum bend radius

T: Thickness
r :reduction of area in tensile

• When R/T=0: Complete

bendability at a tensile
reduction of 50%
 Springback in bending
L8: Sheet metal
forming

Springback equation
3
Ri RiY  RiY 
 4   3  1
Rf ET  ET 
Rf: bend radius after springback
RI: bend radius before springback
Y: yield strength of the material
E: modulus of elasticity of the material
T: thickness of the material
Can Manufacture
L8: Sheet metal
forming

The metal-forming
processes involved in
manufacturing a two-piece
aluminum beverage can.
 Deep Drawing Process
L8: Sheet metal
forming
Significant Variables
• Properties of sheet metal
• Ratio of blank diameter to
punch diameter
• Sheet thickness
• Clearance between the punch
and the die
• Punch and die and corner radii
• Blankholder force
• Friction and lubrication at the
tool/workpiece interface
• Speed of the punch
 Deformation zone L8: Sheet metal
forming
Flange Element:
• High compressive stress in the tangential
direction (σt) - Flange thickens
• Blank holder applies load in the normal
direction (σn) - Prevents wrinkling
• Friction generates force in the radial
direction (σr)

Wall Element:
• High tensile load, stretching in the radial
direction (σr)
• Unsupported region, no friction
• Plane strain
• Failure occurs near punch nose
 Deep Drawing - Force Calculations
L8: Sheet metal
forming

Punch force:
Dp =punch diameter
 D0  t0 = initial blank thickness
Fmax  D p t 0 (Su )  0.7  Su =ultimate tensile strength of blank
D 
 p  D0 = initial blank diameter
 Normal and Average Anisotropy
L8: Sheet metal
forming

Width strain 
Normal anisotropy, R   w
Thickness strain  t
R  2R45  R90
Average anisotropy, Ravg  0
4

Strains on a tensile-test
specimen removed form a
piece of sheet metal. These
strains are used in
determining the normal and
planar anisotropy of the sheet
metal.
Anisotropy and
L8: Sheet metal
Isotropy forming
Deep Drawability (Limiting Drawing Ratio)
L8: Sheet metal
forming
The limiting drawing ratio (LDR) is the maximum ratio of
blank diameter to punch diameter that can be drawn
without failure, Do/Dp
Maximum blank diameter D o
LDR  
Punch diameter Dp

Effect of Average Anisotropy on LDR

Anisotropy and Isotropy
L8: Sheet metal
forming
 Interface : Friction
L8: Sheet metal
forming
• Friction occurs on the interface between both the blank
and the punch as well as the blank and the die.

• While some friction between the punch and the blank is

essential for good drawability, too much friction increases
the load.
Control of material flow by draw-bead
L8: Sheet metal
forming

Metal flow during drawing of a box-shaped part, using

beads to control the movement of the material
 Formability of materials
L8: Sheet metal
forming

Material formability is the ability of sheet

metal to be formed without developing any
failure.

Formability tests:
• Tensile test
• Hydraulic bulge test
• Cupping test
• Forming-limit diagrams
Forming Limit Diagrams
L8: Sheet metal
forming
 Deformation and Tearing in Sheet
Metal During Forming L8: Sheet metal
forming

The deformation of the grid pattern and the tearing of sheet metal during
forming. The major and minor axes of the circles are used to determine
the coordinates on the forming-limit diagram. Source: After S. P. Keeler.