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When
subjected
to
a
tensile
force
there
are
three
deforma+ons
to
be
measured:
the
longitudinal
strain,
the
strain
in
the
width
direc+on
and
the
strain
in
the
thickness
direc+on.
The
material
is
anisotropic.
nance.pipex.com
Shearing:
Shearing
of
sheet
metal
between
two
cu3ng
edges:
(1) just
before
the
punch
contacts
work
(2) punch
begins
to
push
into
work,
causing
plas+c
deforma+on;
(3) punch
compresses
and
penetrates
into
work
causing
a
smooth
cut
surface;
(4) fracture
is
ini+ated
at
the
opposing
cu3ng
edges
which
separates
the
sheet.
Forces
in
a
Shearing
Opera<on
L
=
Total
length
Sheared
t
=
thickness
Percent
Penetra<ons
Material
%
Penetra<on
Silicon
Steel
30
Aluminum
60
.10
C
Steel
Annealed
50
.10
C
Steel
Cold
Rolled
38
.20
C
Steel
Annealed
40
.20
C
Steel
Cold
Rolled
28
.30
C
Steel
Annealed
33
.30
C
Cold
Rolled
22
E.V. crane, Plas+c Working in Presses, John Wiley and Sons, Inc., New York, 1948, p. 36
Fineblanked surface of the same component as shown. (Courtesy of Feintool Equipment Corp., Cincinnati, OH.)
Metal
group
aluminum
alloys
(1100,
5052)
aluminum
alloys
(2024
and
6061);
brass,
so?
cold
rolled
steel,
so?
stainless
steel
cold
rolled
steel,
stainless
steel,
(hard
&
half-hard)
a
_
0.045
0.060
0.075
Example
Es+mate
the
force
required
for
punching
a
25mm
diameter
hole
through
a
3.2mm
thick
annealed
+tanium
alloy
Ti-6Al-4V
sheet
at
room
temperature.
Data:
UTS
=
1000MPa
Cutlery manufacturing:
Trimming:
Cu3ng
scrap
or
excess
material
for
a
fully
or
par+ally
shaped
part
Shaving:
Finishing
opera+on
of
a
previously
cut
edge
by
removing
a
minimum
amount
of
material.
Deep
Drawing
Blanking
Deep
Drawing
Re-drawing
Ironing
Doming
Necking
Seaming
2 2
Do = d1 + d1h Do = d12 + 4d1h
4
4
Formability
Test:
Deforma+on
in
sheet
materials
are
carried
out
by
either
stretching
and/or
drawing.
The
ability
of
the
sheet
to
withstand
large
degrees
of
streching
or
drawing
deforma+on
(shape
change)
without
failure
is
known
as
formability.
Erichsen
Test
Cupping
Test
A
round
punch
is
forced
into
a
clamped
sheet
un+l
a
crack
(sudden
drop
in
force)
appears.
Example:
A
grid
of
2.5mm
circles
is
electroetched
on
a
blank
of
AK
sheet
steel.
Aper
forming
into
a
complex
shape
the
circle
in
the
region
of
cri+cal
strain
is
distorted
into
an
ellipse
with
major
diameter
of
4.5mm
and
minor
diameter
of
2.0mm.
Is
the
component
close
to
failure??
4.5 2.5
Major
strain
1 =
100 = 80%
2.5
2.0 2.5
Minor
strain
2 =
100 = 20%
2.5
The
coordinates
indicate
that
the
part
is
in
imminent
danger.
Maximum Dblank
LDR =
Dpunch
DR =
Dblank
Dpunch
Dblank Dpunch
reduction = r =
Dblank
thickness diameter ratio =
t blank
D blank
The
star+ng
diameter
of
the
blank
must
be
of
the
right
size
for
the
nal
dimensions
of
the
cup
to
be
correct.
Assume
constant
volume
and
neglect
any
thinning
during
the
process.
Example:
Dblank 5.5
DR =
=
= 1.833 < 2
Dpunch 3.0
3 )
(
= 32 = 0.017 > 0.01
5.5
Anisotropy
Ra<o
There
are
two
dierent
types
of
anisotropy
ra+o,
namely,
normal
and
planar
anisotropy
ra+o.
Normal
Anisotropy
Ra<o
(R)
:
Measured
in
a
tensile
specimen,
it
is
the
ra+o
between
the
true
strain
in
the
width
direc+on
and
the
true
strain
in
the
thickness
direc+on.
The
tensile
specimen
must
conform
specic
technical
standards.
The
longitudinal
direc+on
of
the
tensile
specimen
can
be
parallel
or
to
a
certain
angle
with
respect
to
the
rolling
direc+on
of
the
sheet.
width
R=
thickness
R0 + 2R45 + R90
Raverage =
4
R = R45
R0 + R90
2
The
value
of
the
normal
anisotropy
ra+o
determines
the
limi+ng
drawing
ra+o
and
the
value
of
the
planar
anisotropy
ra+o
correlates
with
the
material
propensity
to
earing.
High
values
of
normal
anisotropy
combined
with
low
values
of
planar
anisotropy
provides
op+mal
drawability.
The
maximum
value
of
the
normal
anisotropy
also
depends
on
the
grain
size
of
the
material.
LDR =
Example:
A
special
deep-drawing
steel
showed
a
30%
longitudinal
elonga+on
and
16%
decrease
in
thickness
when
it
is
subjected
to
a
tensile
test.
Es+mate
the
limi+ng
drawing
ra+o
(LDR)
for
this
steel.
l lo
l
= 0.3 = 1.3 ln (1.3) = 0.26236
lo
lo
w wo
w
= 0.16
= 0.84 ln ( 0.84) = 0.1743
wo
wo
ln ( 1
(
(
)
w)
w)
0.84
R=
=
=
= 1.98
ln ( 0.84 1.3)
ln ( h ) ln ( wl
h
wl )
ln wo
ln wo
o o
Drawing Force
(! D $
+
Fmax = Dpt (UTS )*## b && 0.7*)" Dp %
-,
Wrinkling
can
be
reduced
if
a
blankholder
is
loaded
by
maximum
punch
force
The
force
increases
with
increasing
blank
diameter,
thickness,
strength
and
the
ra+o
Bending
Some
sheet
are
bend
along
certain
lines
to
produce
a
desired
shape.
Bending
introduces
plas+c
deforma+on
to
the
part
and
it
should
remain
in
the
desired
shape
(angle)
aper
the
load
is
released.
Spring-back
is
the
part
of
deforma+on
(the
elas+c
part)
that
recovers
in
the
plas+cally
deformed
material
once
the
load
has
been
released.
Original shape
Springback
constant.
In
an
ideal
case,
the
neutral
axis
remains
at
the
center
of
the
sec+on
k=0.5.
In
prac+ce,
k
ranges
from
0.33
(for
R<2t)
to
0.5
(for
R>2t).
Lb = ( R + kt ) = o ( Ro + kt ) = f ( R f + kt )
As
the
part
is
bended,
the
longitudinal
dimension
of
the
at
length
is
increased.
The
bend
allowance
is
the
amount
of
material
that
need
to
be
added
to
the
ange
dimensions
(leg
parts)
in
other
to
develop
a
at
paYern.
Example:
suppose
that
anges
lengths
of
2
and
3
with
an
inside
radius
of
0.250
at
90degrees
are
required.
Then
the
at
dimensions
are
(2-(0.25+0.125))
and
(3-(0.25+0.125)),
i.e
1.625
and
2.625
respec+vely.
The
length
of
the
at
sheet
(bend
allowance)
is
1.625
+
2.625
+
0.457
=
4.707
Bend
deduc<on:
It
is
the
amount
of
material
that
has
to
be
removed
from
the
sum
of
the
anges
to
obtain
a
at
paYern.
! 90 $
Lb = ( R + kt ) = #
& ( 0.250 + 0.33 0.125) = 0.457
" 180 %
Springback
Aper
releasing
the
pressure
of
the
forming
tool,
the
deformed
work-
piece
experience
a
dimensional
change
(strain)
due
to
the
elas+c
recovery
of
the
material.
Sprinback
is
found
in
all
forming
opera+ons,
but
is
is
more
pronounced
in
bending.
As
the
yield
strength
of
the
material
increases
or
as
the
Modulus
of
elas+city
decreases
the
springback
deforma+on
increases.
Overbending,
i.e.
bending
to
a
smaller
radius
of
curvature
than
the
required
can
compensate
for
the
springback
of
the
Original
shape
Desired
deformed
shape
Springback
material.
For
aluminum
alloys
and
austeni+c
steels
the
springback
can
be
approximated
by
the
equa+on
3
! Ro yield $
Ro yield
where
Ro
is
the
radius
of
curvature
before
Ro
= 4#
+1 releasing
the
load
and
Rf
is
the
radius
of
& 3
Rf
Et
" Et %
curvature
aper
releasing
the
load;
t
is
the
thickness,
E
is
the
Modulus
of
Elas+city
and
yield
is
the
yield
stress.
Example
A
0.0359in
thickness
sheet
(20-gage)
is
bent
to
a
radius
of
0.5in.
Calculate
the
radius
of
the
part
aper
it
is
bent
and
the
required
bend
angle
to
achieve
a
90o
bend
aper
springback
has
occurred.
Data:
Yield
Strength=40000psi;
E=29x106psi
3
! Ro yield $
Ro yield
Ro
= 4#
+1
& 3
Rf
Et
" Et %
3
! 0.5 40000 $
0.5
0.5 40000
= 4#
3
+1 = 0.942
&
6
6
" 29 10 0.0359 %
Rf
29 10 0.0359
R f = 0.531in
Lb = o ( Ro + kt ) = f ( R f + kt )
!
!
0.0359 $
0.0359 $
o # 0.5 +
& = 90 # 0.531+
&
"
"
2 %
2 %
o = 95.4 o
Bending Force
K L UTS t 2
Fb =
W
Example:
Es+mate
the
force
required
for
a
90
degrees
bending
of
a
St
50
steel
of
thickness
of
2mm
in
a
V
die.
The
die
opening
can
be
taken
as
eight
+mes
the
thickness.
The
length
of
the
part
is
1m.
Die
Opening
W=8*2=16mm
UTS=500MPa
2
Minimum Bend Radius: On the inside of neutral plane, the metal is compressed, while on
Example:
A
sheet
material
is
to
be
bended
according
to
the
dimensions
given
in
the
gure.
Determine
the
following:
(a)
star+ng
blank
size
and
(b)
the
bending
force
necessary
if
a
V-die
will
be
used
with
a
die
opening
dimension
of
W=1.0.
Data:
E=30000ksi
;
Yield
Strength=40000psi
and
a
tensile
strength=65000psi.
Length
L
=
1.75,
and
the
length
of
the
part
is:
1.5
+1.00
+
BA.
R/t
=
0.187/0.125
=
1.5
<
2.0,
so
Kba
=
0.33
For
an
included
angle
A
=
1200,
then
A
=
600
! 60 $
Lb = ( R + kt ) = #
& ( 0.187 + 0.33 0.125) = 0.239"
" 180 %
Length = 1.5 +1.0 + 0.239 = 2.739"
Force:
Stretch-Forming
The
form
die
is
pressed
into
the
work
with
force
Fdie,
causing
it
to
be
stretched
and
bent
over
the
form.
F
=
stretching
force.
It
is
used
extensively
in
the
aircrap
industry
to
produce
parts
of
large
radius
of
curvature.
The
materials
used
are
very
duc+le.
Spinning
Ideal
for
Lower
produc+on
volumes
Large
parts
Inexpensive
tooling
www.dissco.co.nz
www.ashfordmetalspinning.co.uk
www.tradi+onal-building.com
(a)
Schema+c
illustra+on
of
the
shear-spinning
process
for
making
conical
parts.
The
mandrel
can
be
shaped
so
that
curvilinear
parts
can
be
spun.
(b)
and
(c)
Schema+c
illustra+ons
of
the
tube-spinning
process
Roll Bending
Roll Forming
Electromagne<c
Forming
Sheet
metal
is
deformed
by
mechanical
force
of
an
electromagne+c
eld
induced
in
the
work-piece
by
an
energized
coil.
Presently
the
most
widely
used
HERF
process
Applica+ons:
tubular
parts
A
pinched
aluminum
can,
produced
from
a
pulsed
magne+c
eld
created
by
rapidly
discharging
2
kilojoules
from
a
high
voltage
capacitor
bank
into
a
3-turn
coil
of
heavy
gauge
wire.
Source:
Bert
Hickman,
Stoneridge
Engineering.
Hydroforming
Hydroforming
uses
water
at
high
pressure
to
force
the
piece
into
a
specic
shape.