Sheet Metal Forming
Sheet Metal Forming
Fundamentals and Applications
DEEP DRAWING OF
RECTANGULAR AND ASYMMETRIC
PARTS
MAK 645E
[Link]
Outline of the Module
MAK 645E
[Link]
Introduction to Deep Drawing
Defects in Deep Drawing
Effect of Process Parameters
Tooling and Experimental parts
Blank Holder Force control in
Rectangular pan forming
Introduction to Deep Drawing
Cup Flange:
Compression
and Friction
Zone
Deformation Zone Analysis
Die Radius:
Bending and
Friction Zone
Punch Radius:
Bending and
Friction Zone
MAK 645E
[Link]
Cup Wall:
Fracture Zone
Plane Strain
No Friction
Cup Bottom:
Near Zero Strain
No Friction
3
Introduction to Deep Drawing
Deep Drawing - Rectangular Pan
MAK 645E
[Link]
Tooling for forming Kitchen Sink
MAK 645E
[Link]
Some more examples of Tooling
MAK 645E
[Link]
Defects in Deep Drawing
There are three major defects in deep
drawing of rectangular pans.
Flange Wrinkles
Side Wall Wrinkles (Puckering)
Tearing (Fracture)
MAK 645E
[Link]
Prediction of Buckling
Flange Wrinkles
Side Wall Wrinkles
DIE CAVITY WALL
MAK 645E
[Link]
PAN WALL
PUNCH WALL
Minimizing Buckling
Minimize Flange Wrinkles: Minimize Side Wall Wrinkles:
Increase Blank Holder Force
Increase Material Thickness
Increase Normal Anisotropy
Decrease Planar Anisotropy
MAK 645E Flange Wrinkles
[Link]
Increase Material Thickness
Increase Normal Anisotropy
Decrease Planar Anisotropy
Increase Blank Holder Force
Increase Blank Diameter
Increase Blank Holder/Sheet Friction
Use Drawbeads
Side Wall Wrinkles
Prediction of Wrinkling
Prediction of Wrinkling in
Cabin LH Rear Inner Panel
BHF = 10 tons
BHF = 30 tons
Agrees with experimental observations
MAK 645E
[Link]
10
Prediction of Wrinkling
Prediction of Wrinkling in
Deck Lid Outer using PAM-STAMPTM
MAK 645E
[Link]
11
Tearing (Fracture)
Tearing of Rectangular pan
MAK 645E
[Link]
12
Prediction of Fracture
Possible
Tearing
Fracture
MAK 645E
[Link]
13
Effect of Process Parameters
Effect of Blank Holder Force (BHF)
BLANK
HOLDER
FORCE
BLANK
HOLDER
BLANK
HOLDER
FORCE
PUNCH
BLANK
HOLDER
DIE
CAVITY
DIE
CAVITY
SHEET
Increasing the BHF tends to increase sheet tension and
fracture, while decreasing springback and wrinkling
MAK 645E
[Link]
14
Effect of Process Parameters
Limit of
Tearing
Draw Depth
Limit of
Wrinkling
Effect of Blank
Holder Force
(BHF)
Drawability Window
MAK 645E
[Link]
Blank Holder Force
Variable BHF results in
improved draw depth of
the rectangular pan as
compared to constant
BHF
15
Effect of Process Parameters
Effect of Blank Shape
r
R
Rectangular Blank
Decreasing the blank size tends
to promote metal flow and
MAKdecrease
645E
fracture
[Link]
Chamfered Blank
Effective Draw Ratio
R
r
16
Effect of Process Parameters
Effect of Friction
BLANK HOLDER/
SHEET FRICTION
Increasing the binder friction
tends to increase sheet
tension. Increasing the punch
friction tends to reduce stretch
performance but increases
drawing performance.
PUNCH/
SHEET
FRICTION
MAK 645E
[Link]
Binder Region
Punch Region
Drawing
More friction,
Lower performance
More friction,
Higher performance
Stretching
More friction,
Higher performance
More friction,
Lower performance
17
Effect of Material Parameters
Effect of K-value
700
MAK 645E
[Link]
T rue S tress (G P a)
Increasing the Kvalue tends to
increase deformation
stresses, tool
pressures, and spring
back.
Increasing
K-value
600
= K [ 0 + ]n
500
400
300
200
100
0
0
0.5
1.5
True Strain
K=500 GPa
---K=600 GPa
2.5
18
Effect of Material Parameters
Effect of n-value
700
Increasing
n-value
T rue S tress (G P a)
600
= K [ 0 + ]n
ln( LDR ) =
1.1
500
( n +1)
( n + 1)
LDR = limiting draw ratio
n = strain hardening exponent
= efficiency factor
(Zunkler, 1973)
400
300
200
100
0
0
MAK 645E
[Link]
0.5
1.5
True Strain
n=0.200
n=0.300
2.5
Increasing the n-value tends
to increase strain hardening
and LDR and decrease
fracture, while decreasing
deformation stresses, tool
pressures, and springback.
19
Effect of Material Parameters
Effect of
Normal Anisotropy (rm)
= x 2 + y 2 x y
2r
r +1
Increasing normal anisotropy
decreases flow stress in regions
of drawing and increases flow
stress in regions of stretching,
thus it improves drawability.
MAK 645E
[Link]
20
10
Design Issues
Tooling design include:
Binder Development (flat, sloped, curved, etc.)
Addendum Design (die radius, drawwall, etc.)
Pad Design (location, actuation, etc.)
Drawbeads (location, cross section)
Actuation (press type, nitrogen cylinders, etc.)
Punch/Die Clearance
Tool Material and Coatings
MAK 645E
[Link]
21
Dies & Tooling
Conventional Press Actions
a)
b)
MAK 645E
[Link]
Single Action Press
Double Action Press
Double Action with Cushion
c)
22
11
Drawbead Design
Drawbead Configuration in Stamping
MAK 645E
[Link]
23
Drawbead Design
Drawbead Configuration around Die Cavity
MAK 645E
[Link]
24
12
ERC Rectangular Pan Tooling
Die
Blank
Blank
Holder
Punch
FE model of Rectangular Pan Drawing
Rectangular Pan Geometry
MAK 645E
[Link]
25
Experimental Rectangular Pans
AKDQ Steel Rectangular Pans
AKDQ Steel, Rectangular
2 Draw, Plan View
MAK 645E
[Link]
AKDQ Steel, Chamfered
2 Draw, Plan View
26
13
Blank Holder
Defects can be avoided in rectangular part
drawing by the application of Blank Holder
Force (BHF). This BHF can be applied either by
hydraulic cushion pins or nitrogen cylinders.
The applied BHF profiles can be
Constant in time and space
Variable in time alone (temporal variation)
Variable in space alone (spatial variation)
Variable in time and space
MAK 645E
[Link]
27
Some Variable BHF trajectories
MAK 645E
[Link]
28
14
Variations in BHF Application
Constant in location, constant with stroke (current practice)
- Each cushion pin/nitrogen cylinder has same force applied that is held
constant with stroke
- Nitrogen cylinders, Force Modulator (FM) systems, single-point
hydraulic cushions
Constant in location, variable with stroke
- Each cushion pin has same force applied that is varied with stroke
- Single-point hydraulic cushions, FM systems
Variable in location, constant with stroke
- Each cushion pin has different force applied that is held constant with
stroke
- Nitrogen cylinders, FM systems, multi-point hydraulic cushions
Variable in location, variable with stroke
- Each cushion pin has different force applied that is varied with stroke
MAK 645E
- FM systems, Multi-point hydraulic cushions
[Link]
29
Types of Blank Holders
MAK 645E
[Link]
30
15
Nitrogen Cylinders at ERC
Variable spatial BHF profiles can be applied with the
help of nitrogen cushion pins, which exert force on
the blank holder by deforming it elastically.
MAK 645E
[Link]
31
Segmented Blank Holder
Siegert, 1995
MAK 645E
[Link]
32
16
Flexible Blank Holder
Siegert, 2000
MAK 645E
[Link]
33
Blank Holder Force Control
Issues with Multi-point Cushion Systems
Blank Holder Force (kN)
Cushion pin 1
480
400
320
240
160
80
0
0
10
20
30
40
50
60
Punch Stroke (mm)
BHF for cushion pin 1
Blank Holder Force (kN)
..
Cushion pin 15
480
400
320
240
160
80
0
Problem: How to determine the variation of
BHF for each cushion pin ?
MAK 645E
[Link]
10
20
30
40
50
60
Punch Stroke (mm)
BHF for cushion pin 15
34
17