Beruflich Dokumente
Kultur Dokumente
RWTH Aachen
Topic 11:
Formability of thin sheet
Outline
Outline
- shearing
- bending
- stretching
- deep drawing
Possible failure mechanisms during forming
- fracture
- necking
- wrinkling
- dimensional inaccuracy
Principles of sheet metal forming
Definitions
Outline
3
1
3
1
3 = 0.577Y
1
II
3
V
1
III
- 1
+Y
1 = 23 = 1.155Y
VI
- 1
1 = 21
+Y
2 = 0
+Y
21+ 23 13 = Y2
-Y
2 = 0
Pure shear
1 = - 3
IV
+Y
1 = 0.577Y, 3= - 0.577Y
-Y
1
- 3
- 3
y / k f
r=
5
1000
TRIP
r=
0
r=
1
IV
x/kf
r=
3
800
600
DP
IF-HS
FeP04
400
IF
200
x uniform elongation
0
III
II
0,1
True strain
0,2
0,3
x uniform elongation
1600
6000
Temperature:
Strain hardening , MPa
3000
1200
4000
DP
2000
TRIP
1000
IF-HS
FeP04
0
0
0,1
True strain
IF
800
400
0,2
0,3
4000
2000
0
0
0,2
0,4
True strain
0,2
0,4
True strain
60
Fe P05
FLD0
40
Major strain
ZStE 300
Al 5182
30
Increasing:
thickness
n-value
r-value
lubrication
20
10
thickness: 0,9 mm
0
-20
-10
10
20
30
40
Minor strain 2
50
Minor strain 2, %
ng
1= 2
hD
raw
i ng
i
aw
Dr
win
Dra
ple
Sim
ep
De
1 = ln (l1 / d)
2= 0
plane strain
1= -22
S tr
etc
1= - 2
Major strain 1
Major strain 1, %
50
2 = ln (l2 / d)
d
l2
l1
0
Minor strain 2
Outline
t
Deep Drawing
Stretch Drawing
1.
2.
crack
deformed
area
1. flange
2. wall
deformed
area
crack
3. bottom
3.
Stress states during deep drawing
n-value
r-value
Flow curve
nation
s
l
b
Result
2.4
15
2.3
Earning h/h, %
Determi-
Definition
2.2
2.1
2.0
10
0
0
0.5
1.0
1.5
2.0
0.3
2.5
0.4
0.7
0.8
T
T
T
T
0.6
t0
r0
0.5
Planar anisotropy r
Normal anisotropy rm
measuring point
rd
rd
D E F
ri
r0
1. punch
2. die
3. blank holder
rc
rc
0,6
scatter band mild steels
DP 500 non
temper rolled
R
Major strain 1
Rc
0,4
Fe P04
Fe P04
0,2
SLR
DP 500 non
temper rolled
DP 500 temper rolled
Rc
0,0
-0,4
-0,2
0,0
0,4
0,2
Minor strain 2
R = punch radius
target
press shop
design
material
component
strain
distribution
FLC
comparison
Z <=> G
analysis
Z << G
result
Z < G
okay, change
steel grade
conclusion
Z >- G
1. change
forming
operation
okay
2. change steel
grade
3. change design
Outline
Tearing
Fracture
Fracture
Sa
fe
Wrinkling
Compression
fo
rm
in
g
re
gi
on
2
Damage
-2
1
1000
Average length of
Inclusion : 2,45 m
Strutural steel
800
v,i = exp -
3
2
m
v
600
Gurson Modell:
400
200
Average length of
inclusion: 4,50 m
20
40
60
80
Tension test
2 f cosh
kk
- (1 + f 2) = 0
2 m
Rousselier Modell:
Metallography
eq
m
F = + D 1 f exp - R (p)
1
IF - Steel
v 2
+
m
FE- calculation
S 460 M F/B/P
S 460 M B/M
S 460 M M ann.
S 460 M M
S 460 M F/P
IF (G = 3,7)
IF (G = 5,4)
comparison
Equivalent strain pv
IF
1,5
1
S 460 M F/B/P
1,5
S 460 M M ann.
0
0,3
0,6
0,9
1,2
1,5
1,8
2,1
Stress triaxiality m / v
Equivalent strain pv
IF
1,5
effect of strength
S 460 M F/B/P
effect of cleanliness
1,5
S 460 M M ann.
0
0,3
0,6
0,9
1,2
1,5
1,8
2,1
Stress triaxiality m / v