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(PPT) Drawing 1

This document discusses various concepts related to sheet metal forming processes. It describes how major and minor strains behave during stretching, with the major strain always being positive and the minor strain being either positive, negative, or zero. It also discusses forming limit diagrams and the safe and failure zones for different metals. Key aspects that influence processes like deep drawing are reviewed, such as blank diameter, clearance, material properties, thickness, lubrication. The document also examines topics like earing, bending, springback, and how normal and planar anisotropies impact formability.

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394 views29 pages

(PPT) Drawing 1

This document discusses various concepts related to sheet metal forming processes. It describes how major and minor strains behave during stretching, with the major strain always being positive and the minor strain being either positive, negative, or zero. It also discusses forming limit diagrams and the safe and failure zones for different metals. Key aspects that influence processes like deep drawing are reviewed, such as blank diameter, clearance, material properties, thickness, lubrication. The document also examines topics like earing, bending, springback, and how normal and planar anisotropies impact formability.

Uploaded by

AXEL
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Chapter 16

Lecture 2
Sheet Metal Forming

Figure 16.14a: Major Strain and Minor Strain

During stretching in sheet metal, Volume


constant
l + w + t = 0
Major strain always larger than minor
strain
Major strain always larger than 0
Minor strain can be either positive and
negative or zero

Plane strain
Minor strain is 0
l + w + t = 0,
thus l + t = 0

Figure 16.14b: Forming-limit Diagrams (FLD)

Engineering
strains

Although the major strain is always positive (stretching), the minor strain may
be either positive or negative or zero

Safe Zone and Failure Zone for Al

Failure zone for Al


Safe zone
for aluminum

Although the major strain is always positive (stretching), the minor strain may
be either positive or negative or zero

Safe Zone and Failure Zone

Failure zone
for high strength steel
Safe zone
for high strength steel

Although the major strain is always positive (stretching), the minor strain may
be either positive or negative or zero

Safe Zone and Failure Zone


Failure zone
for low carbon steel
Safe zone
for low carbon steel

Although the major strain is always positive (stretching), the minor strain may
be either positive or negative or zero

Figure 16.14b: Forming-limit Diagrams (FLD)

Figur 16.31:
Steps in
Manufacturing
an Aluminum
Can

Methods for Reducing the Diameter of


Drawn Cups
Conventional redrawing

Methods for Reducing the Diameter of


Drawn Cups
Reverse redrawing
Blank holder for first draw

Punch for first draw = drawing ring for redraw

Drawing
ring for first
draw
Blankholder for reverse redrawing

Punch for reverse redrawing

Ironing
Process:
Die reduces workpiece
thickness around punch
Application:
Tubular products, cans
Key Process Variables:
Friction
Thickness reduction
Punch velocity
Tooling geometry
Process sequence

Punch
Workpiece

Die

Deep Drawing

Figure 16.32 (a) Schematic illustration of the deep-drawing process on a


circular sheet-metal blank. The stripper ring facilitates the removal of the
formed cup from the punch. (b) Process variables in deep drawing. Except
for the punch force, F, all the parameters indicated in the figure are
independent variables.

Deep Drawing
Process factors influencing the force in Deep
Drawing

Blank diameter
Clearance
Material
Thickness
Blank holder force
Blank holder friction
Lubrication

Deep Drawability

Limiting Drawing Ratio (LDR)


LDR = D0/Dp
D0 : Maximum Blank diameter
Dp : Punch Diameter
Unfortunately, Very difficult to get this ratio (time consuming)
Fortunately, closely related to Normal Anisotropy

Figure 16.45: Earing

Earing
Effect of Planar Anisotropy on Earing

R<
0
0

45

R>
0
90

45

R = w / t
90

Rolling Direction

R0 R90 2 R45
2

45

90

Rolling Direction

45

90

Bending

Figure 16.16 Bending terminology. Note that the bend radius is measured to
the inner surface of the bent part.

R/T Ratio versus % Area Reduction


Equation 16.5*,
minimum bend
radius, R,
R = T [50/ra 1]
The ra is tensile
reduction area

Figure 16.18 Relationship between R/T ratio


and tensile reduction of area for sheet metals.
Note that sheet metal with a 50% tensile
reduction of area can be bent over itself, in a
process like the folding of a piece of paper,

Springback

Figure 16.19 Springback in bending. The part


tends to recover elastically after ending, and its
bend radius becomes larger. Under certain
conditions, it is possible for the final bend angle
to be smaller than the original angle (negative
springback).

Reducing or eliminating Springback

Bending force :
Maximum bending force, P = KYLT 2
W
K constant ranges from 0.3(wiping die) 0.7(u-die)-1.3(V-die)
Y yield stress
L- length of the bend
T- thickness of sheet

For a V-die
Max bending force, P = (UTS)LT 2
W
UTS Ultimate tensile strength

Bend allowance :

Lb = alf ( R + KT)
Alf bend angle (radians)
T-sheet thickness
R-bend radius
K-constant
Bend allowance for ideal case the sheet thickness ;k=0.5
Lb = alf(R+(T/2))
In practice the value of K ranges from 0.33-0.5
Minimum bend radius
Engineering strain on a sheet during bending
E = 1 / (2R/T)+1
As R/T decreases,tensile strain at outer fiber increases and material
cracks
Ratio at which the crack appears on outer surface is minimum bend
radius

Spring back :
In Bending ,after plastic deformation there is an elastic recovery this
recovery is called spring back.
Spring back can be calculated approximately in terms if radii Ri and
Rf
Ri/Rf = 4 ( Ri Y / ET )3 3 (Ri Y /ET) + 1
Spring back Increases as (R/T ratio & yield stress of material )
increases as elastic modulus E decreases

Fig 16.19 Spring back in bending .The part


tends to recover elastically after
ending,and its bend radius becomes
larger.Under certain conditions,it is
possible for the final bend angle to be
smaller than the original angle(negative
spring)

Video clip for Drawing process

Normal Anisotropy
Normal anisotropy: R = w /
t
Remember: l + w + t = 0
Simple tension, R =1.0

Determines thinning
behavior of sheet metals
during stretching; important
in deep-drawing operations
Tensile tests determine
normal anisotropy

Figure 16.33 Strains on a tensile-test


specimen removed from a piece of sheet
metal. These strains are used in
determining the normal and planar
anisotropy of the sheet metal.

Average Normal Anisotropy


Normal anisotropy (r)
r 0o
r 45o
Rolling
Direction

r 90o

Average Normal Anisotropy


Rave = (R0 + 2R45 +R90)/4

Average Normal Anisotropy Vs Limiting


Drawing Ratio
Figure 16.34 The
relationship between average
normal anisotropy and the
limiting drawing ratio for
various sheet metals

Limiting Drawing Ratio (LDR)


LDR = D0/Dp
D0 : Maximum Blank diameter
Dp : Punch Diameter

Typical Range of Average Normal


Anisotropy, R, for Various Sheet Metals
TABLE16.4
Zincalloys
Hotrolledsteel
Coldrolledrimmedsteel
Coldrolledaluminumkilledsteel
Aluminumalloys
Copperandbrass
Titaniumalloys(a)
Stainlesssteels
Highstrengthlowalloysteels

0.40.6
0.81.0
1.01.4
1.41.8
0.60.8
0.60.9
3.05.0
0.91.2
0.91.2

Planar Anisotropy (Earing Tendency)


Planar Anisotropy
Rave = (R0 -2R45 +R90)/2

Normal anisotropy
(r)

r 0o
r 45o

Rolling
Direction

r 90o

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