ERC

Sheet Metal Forming NSM

Sheet Metal Forming

Fundamentals and Application
S1 INTRODUCTION
Engineering Research Center For Net Shape Manufacturing
The Ohio State University, Columbus, Ohio

Ph:614-292-9267
Fax:614-292-7219
http://www.ercnsm.org

Slide S1.1
 ERC
Automotive Components NSM

Daimler-Benz, 1997
Slide S1.2
 Characteristics Of ERC
Sheet Forming Processes NSM
Incoming material is sheet blank of partially
formed workpiece (thin section)

Deformation causes significant changes in

shape, but little change in thickness (although
variations in thickness are very important)

Elastic recovery is important to maintain

shape and tolerances

Slide S1.3
 ERC
Blanking NSM

Phases of the Blanking Process

Courtesy: Schuler Inc.

Slide S1.4
 Blanking ERC
NSM

Application:
Electrical connectors
Blanks for stamping

(Schuler, 1998)
Key Process Variables:
Friction
Punch / Die clearance
Punch velocity
Tooling geometry

Blanking
(Kalpakjian, 1997) Slide S1.5
 Piercing ERC
NSM
punch motion

Piercing: the inner form of a

workpiece is obtained, the pierced
punch
stripper piece is generally scrap.

workpiece

die

Piercing

(Kalpakjian, 1997) Slide S1.6

Fine Blanking ERC
NSM

Fine Blanking
Courtesy: Schuler Inc.
Slide S1.7
 Trimming ERC
NSM
Trimming: to shear from a workpiece a
particular portion which is not required on the
final product.

Trimming (Kalpakjian, 1997)

Slide S1.8
 ERC
Air Bending
NSM
Sheet Bending: Forming of some finite curvature on (usually) flat
sheet metal along a straight edge.

Slide S1.9
 ERC
Air Bending
NSM
Air Bending Simulation Results
Click on figure to see simulation

Slide S1.10
 ERC
Die Bending
NSM

Die Bending
Courtesy: Schuler Inc.

Slide S1.11
 ERC
Roll Bending
NSM

Roll Bending
Courtesy: Schuler Inc. Slide S1.12
 ERC
Swivel Bending
NSM

Swivel Bending
Courtesy: Schuler Inc.
Slide S1.13
 ERC
Circular Bending
NSM

Circular Bending
Courtesy: Schuler Inc. Slide S1.14
 ERC
Bendability of Materials
NSM
Bendability chart for Low Carbon Steel

r: percent reduction
of area in a tensile
test

(Kalpakjian,1997)
Slide S1.15
 ERC
Flanging
NSM
Flanging: a process of bending the sheet metal about a
straight or curved edge.

PUNCH
BLANKHOLDER

DIE

Die

Punch Pad

Initial Final Springback

Slide S1.16
 ERC
Flanging
NSM
Click below to see animation
of flanging process

Slide S1.17
 ERC
Flanging NSM

Straight Flange Stretch Flange Shrink Flange

Reverse Flange Jogged Flange Hole Flange

Slide S1.18
 ERC
Hole Flanging
NSM

Courtesy: Schuler Inc.

Slide S1.19
 Various Geometric ERC
Configurations of Hems NSM
Convex edge-
Convex surface

Inner Panel

Concave edge-
Convex surface Outer Panel

CORNER Straight edge-

(Convex edge) Straight surface
Side View
Inside View
Slide S1.20
 ERC
Hemming NSM
In hemming process the edge of the sheet is folded over itself.

Improved
appearance

Increased
stiffness

Eliminated
sharp edges

Slide S1.21
 ERC
Types of Hems NSM

Flattened Hem Open Hem Teardrop Hem

Radius Flat Hem Modified Flat Hem

4t - 6t

Rope Hem Modified Rope Hem

Slide S1.22
 ERC
Hemming NSM

Click figure below to see the

animation of hemming process

Joining by Forming: Hemming

Courtesy: Schuler Inc.

Slide S1.23
 ERC
Roll Forming NSM

Process:
Shaped rolls form long,
constant cross-section
parts

Application:
Siding, channel, cable
trays, welded tubes

Key Process Variables:

Forming sequence
Friction
Tool geometry

Courtesy: Schuler Inc.

Slide S1.24
 ERC
Spinning a Hollow Body NSM

Spinning a Hollow Body

Courtesy: Schuler Inc.

Slide S1.25
 ERC
Expanding by Stretching NSM

Expanding by Stretching
Courtesy: Schuler Inc.
Slide S1.26
 ERC
Embossing NSM

Embossing
Courtesy: Schuler Inc.

Slide S1.27
 ERC
Stretch Forming NSM
Forming
Force
Blank Holder
Force

Lockbeads
Intentional Thinning
(Schuler, 1998)
Slide S1.28
 ERC
Stretch Forming NSM

Stretch Forming
Courtesy: Schuler Inc.

Slide S1.29
 ERC
Deep Drawing NSM
In Deep Drawing, a flat sheet-metal blank is formed into a cylindrical
or box-shaped part by means of a punch that presses the blank into
the die cavity.

Significant Variables:
Properties of sheet metal
Ratio of blank diameter to
punch diameter
Sheet thickness
Punch and die corner radii
Blank holder force
Friction and lubrication
Speed of punch
Clearance between punch
and die

Slide S1.30
 ERC
Deep Drawn Part Samples
NSM

Deep Drawn
Cup Part

Deep Drawn
Deep Drawn Fender
Rectangular Part

Slide S1.31
Single-draw Deep Drawing with ERC
Blank Holder NSM

Single-draw Deep Drawing with Blank Holder

Courtesy: Schuler Inc.

Slide S1.32
 ERC
Deep Drawing without Blank Holder
NSM
When drawing without a blank holder, the die is given a special geometric
shape. The optimal die shape with respect to drawing load and limiting
drawing ratio is the tractrix shape as shown below. Since exact tractrix is
difficult to manufacture, it is often replaced by an approximate tractrix
shape.

Deep drawing
without blank
holder

Exact tractrix die

shape
Approximate
tractrix shape
[Lange,1985]
Slide S1.33
 ERC
Deep Drawing with Draw bead
NSM

Binder holder Punch

Die Draw bead

Deep drawing with drawbead

Courtesy: Schuler Inc.

Slide S1.34
 ERC
Deep Drawing and Redrawing
NSM

Multiple-draw Deep Drawing with Telescopic Punch

Courtesy: Schuler Inc.
Slide S1.35
 ERC
Reverse Drawing
NSM

Reverse Drawing
Courtesy: Schuler Inc.

Slide S1.36
 ERC
Progressive Deep Drawing
NSM

First Second Third Fourth Fifth Sixth

Forming sequence: from left to right/ forming stages are
indicated with an arrow; Courtesy: PAX Machine Works Inc.

Courtesy: Schuler Inc. Slide S1.37

 ERC
Hydromechanical Deep Drawing
NSM

Hydromechanical Deep Drawing

Courtesy: Schuler Inc.

Slide S1.38
 ERC
Rubber Forming NSM

Slide S1.39
 ERC
Sheet Hydroforming
NSM
Sheet hydroforming can be achieved, by two different
modes of increasing the hydrostatic pressure.

Active sheet hydroforming Passive sheet hydroforming

( Combination of hydraulic stretch forming followed (Hydromechanical deep-drawing of
by reverse drawing and Hydromechanical deep- sheet metal parts with convex/concave
drawing, Siegert et al.) contours, Aust et al.)

Slide S1.40
 ERC
Flexforming NSM

The Principle of Flexforming

Courtesy: ABB
Slide S1.41
 ERC
Flexforming NSM
Click figure below to see the animation of flexforming in DEFORM2D

Slide S1.42
 ERC
Tube Hydroforming NSM

Process:
Fluid pressure forms tube
into die

Application:
Complex tubular shapes,
automotive

Key Process Variables:

Geometry
Tube thickness
Friction
Fluid medium
Slide S1.43
 ERC
Tube Hydroforming NSM
What is Tube Hydroforming?

(1) Place the blank tube into tooling (2) Seal the ends and fill with fluid

(4) Open the tooling, remove the part (3) Increase pressure, move punches

Slide S1.44
 ERC
Tube Hydroformed Parts NSM

Tee shape

Y shape
Bend
Slide S1.45
 Characteristics of ERC
Hybrid Processes NSM

Hybrid Processes have characteristics of both sheet

and bulk forming operations

Often a part is first formed from sheet, plate, or billet

and then formed to obtain large reduction in
thickness

Examples:
Coining, Ironing

Slide S1.46
 ERC
Ironing NSM
Process:
Die reduces workpiece
thickness around punch

Applications:
Tubular products
Beverage cans

Key Process Variables:

Friction
Thickness reduction
Punch velocity
Tooling geometry Courtesy: Schuler Inc.
Process sequence Slide S1.47
 ERC
Can Manufacturing
NSM

Deep Drawn Cups Ironed in Several Dies

Courtesy: Schuler Inc.
Slide S1.48
 ERC
References
NSM
[Altan, 1983] Altan, T., Oh, S., and Gegel, H. L., Metal Forming:
Fundamentals and Applications, American Society for Metals,
1983
[Hosford,1983] Hosford, W.F., Caddell, R.M., Metal forming Mechanics and
Metallurgy, Prentice Hall, 1983
[Kalpakjian,1997] Kalpakjian, S., Manufacturing Processes for Engineering
Material, Addison-Wesley, 1997
[Lange, 1985] Lange, K., Handbook of Metal Forming, McGraw-Hill
Publishers, 1985
[Siegert, 2000] Klaus Siegert, Markus, H., Bruno, L., Ralf, R., Recent
developments in hydroforming technology, Journal of
Materials Processing Technology, vol 98, pp 251-258
[Schuler, 1998] Schuler Gmbh, Metal forming handbook, Springer
Verlag,1998

Slide S1.49
 ERC
NSM

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Slide S1.50