BIW Manufacturing Process

BIW Manufacturing Process
STAMPING MACHINES
Mechanical and hydraulic presses are commonly used for press
operation due to wide range of sizes, tonnage capacities, stroke
lengths, and operating speeds.
Mechanical presses are suited for:
Blanking parts at high speed

Automatically fed with a short feed length
Shallow drawing
Work requiring an easily controlled depth of stroke
Hydraulic presses are suited for:
Deep drawing
Short runs with frequent die changes
Blanking with a form, or coin
Lower speed high tonnage blanking with long feed lengths
Work requiring repeatable pressure
DESIGN FOR STAMPING:
To finalize optimized stamping process it is the responsibility of

product designer and die designer to:
1. Simplify the design suitable for die design or combination

of operations
2. Design a components such that it will combine the
components in case of tailor welded blanks
3. Reduce depth of component to avoid number of draw
operations
4. Minimize number of operations required to finish the
components
5. Process to be choose for stamping depends on the design
and complexity of component
6. Usually blanking, drawing, piercing, forming, notching,
trimming, hemming operations are largely used in
automotive stamping applications
SHEET METAL PREPARATION FOR PRESS OPERATION:
Normally sheets are supplied in the form of rolls for

BASIC OPERATIONS:
Blanking: Cutting of flat sheet to the

approximate size of the component
Drawing / forming: Flat sheet shaping as per
the desired component
Cam piercing: If side piercing is not
possible in draw then cam piercing can be done as post
operation
Piercing / notching / hemming: These are post operations
as per the design requirements
Trimming: It is the last operation to
remove the extra material from final component
SHEET METAL FORMING OPERATIONS
There are several processes involved in making final

component from raw material. For understanding
purpose these are divided into three classifications:
Shearing process (Cutting material)
Punching
Blanking
Perforating
Parting
Notching
Lancing
Nibbling
Slitting
Tailor welded blank
Shear Spinning
Forming process (Bending and stretching)
Bending
Stretching
Drawing
Re-draw
Roll forming
Explosive forming
Hydro forming
Finishing process (to maintain surface and
geometry quality)
Trimming / laser trimming
Flanging / Cam flanging
Hemming
Part off
Beading
DEFECTS & TEST METHODS FOR FORMABILITY OF SHEET
METALS
1. Yield point elongation :

Stress strain marks can be eliminated by reducing
sheet 0.5 to 1.5% thickness
2. Anisotropy:
It is caused by thermo-mechanical processing of
sheet (Types: Crystallographic anisotropy
/ Mechanical fibering)
These strains are used in determining the
normal and planar anisotropy of sheet metal
3. Grain size:
Grain size effects mechanical properties & surface
appearance due to stretching and drawing
The coarser the grain the rougher the appearance
4. Cupping test:
Determine the formability of sheet metals
FORMING DEFECTS IN SHEET METALS
1. Earing or planer anisotropy:

Edges of drawn cups may be wavy due to varying
properties in different directions, this phenomenon is
called earing
2. Wrinkling in flange:
Due to compressive buckling
in circumferential direction
3. Wrinkling in wall:
When a wrinkled flange is drawn into the cup or if the
clearance is very large, resulting in a large
suspended region
4. Tearing:
Because of high tensile stresses that cause thinning
and failure of the metal in the cup wall
Tearing can also occur in a drawing process if the die
has a sharp corner radius
5. Surface scratches:
Can be seen on the drawn part if the punch and die
are not smooth or if the lubrication of the process is
poor
6. Spring back:
After plastic deformation there is an elastic recovery
this recovery is called spring back
7. Necking:
Thinning abruptly in narrow area
8. Stretching:
Extension of sheet surface along all directions
Friction between the blank, blank holder, punch and die
cavity
Clearances between the blank, blank holder, punch and die
cavity
Blank shape and thickness
Final part geometry
Punch speed
HOW TO AVOID DEFECTS IN DIE DESIGN
Forming analysis
Forming limit diagram simulation
Draw ratio selection
Proper blank holding pressure
Provision of draw beads for helping flow of material

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Mechanical presses are suited for:

Blanking parts at high speed

Hydraulic presses are suited for:

DESIGN FOR STAMPING:

To finalize optimized stamping process it is the responsibility of

1. Simplify the design suitable for die design or combination

SHEET METAL PREPARATION FOR PRESS OPERATION:

Normally sheets are supplied in the form of rolls for

Blanking: Cutting of flat sheet to the

SHEET METAL FORMING OPERATIONS

There are several processes involved in making final

1. Yield point elongation :

FORMING DEFECTS IN SHEET METALS

1. Earing or planer anisotropy:

HOW TO AVOID DEFECTS IN DIE DESIGN

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