Sheet Metal Forming
Body parts in a car
Industrial Applications
Automotive sheet materials
iitdelhi
Dr. D. Ravi Kumar, Department of Mechanical Engineering, IIT Delhi
4
Other sheet materials used
Stainless steel sheets: domestic utensils, pipelines
Galvanised steel sheets: Roofs, outer panels
Hot rolled steel sheets: thick walled containers, LPG
cylinders
Al and Ti alloy sheets: Aerospace applications,
Beverage cans etc.
Zr alloy sheets: Nuclear fuel assembly
High strength materials (Ni alloys etc.): turbine blades,
space research, other special purposes.
Basic Sheet metal forming processes
• Deep Drawing
• Stretch-forming
• Bending
• Shearing
Stresses applied in sheet metal forming are
primarily tensile though some compressive
stresses are generated.
Most sheet stampings are produced by
combination two or more of the above processes.
Sheet metal forming equipment
• Presses: Mechanical, Hydraulic, Pneumatic
• Single action, Double action and Triple
action presses are available.
Deep Drawing
A metal working process
used to produce cup
shaped components from
flat sheets.
Ex. Bath tubs, oil sump,
LPG cylinders,
automotive panels,
utensils etc.
Blank holder is required
to hold down the sheet
with required force and to
prevent wrinkling.
Deep Drawing
Fig. 1.2 Deep drawing of a cylindrical cup (a) before drawing and (b) after drawing
[Dieter 1988].
Deep drawing on a double/triple action
hydraulic press
Different regions during drawing
Thickness variation
➢ Significant thickening takes place in the flange
due to compressive stresses. Thinning occurs due
to bending and unbending over the die radius.
➢ Maximum thinning occurs in the cup wall which
is essentially subjected to plane strain stretching.
➢ Because of little deformation in the bottom, no
significant change in thickness occurs in this
region.
Thickness variation
Failure in Deep drawing
• Failure occurs in the
cup wall just above the
punch corner (due to
plane strain stretching
and thinning) by
necking or tearing
when the stress
exceeds UTS in plane
strain condition.
Blank size Calculation
Thickness (t) is assumed to remain constant.
D h
dh + d2/4 = D2/4
d
D2 = d2 + 4dh
Draw ratio is the ratio of initial blank diameter to the
cup diameter or punch diameter.
Limiting Draw ratio
Depth of the cup increases as the initial blank diameter
increases but this also increases the draw ratio. This in
turn requires higher force which may cause failure
when the cup wall can not support the force applied.
This puts a limit on the allowable draw ratio.
Drawability
Drawability of a sheet is the extent to which a sheet
can be drawn. It is quantitatively measured by
limiting draw ratio (LDR). It represents the largest
blank that can be drawn into a die without
failure/tearing.
Drawability
• LDR = D0 max/Dcup = Do max/Dp
• LDR (theoretically) = exp ()
where is the efficiency factor which accounts for
friction etc.
• Under ideal conditions ( =1), max LDR that can
be achieved is 2.71. But even for very ductile
metals, it is difficult to draw with LDR > 2.3. So
to produce much deeper cups, drawing is done in
several stages.
Drawability
• Material properties:
• Design parameters
• Process parameters
Design variables
Process variables
• Blank holding pressure: Insufficient blank
holding pressure causes wrinkling during
drawing and a high BHP causes tearing at
the die throat.
• Lubrication: Lubrication between blank and
the die helps reduce the drawing force and
hence drawability improves.
Wrinkling
Optimum conditions
• Die corner radius : about 5-10 t
• Punch corner radius: sharp corner leads to
thinning and tearing, about 2-5t
• Clearance: usually around 1.1-1.2 t
• Blank holder pressure: 2% of average of YS
and UTS
• Lubrication: Between die and the blank
Material properties
• Strength and Ductility
• Work hardening exponent
• Anisotropy
Anisotropy
• Drawability (measured in terms of LDR)
increases with increase in Average Plastic
strain ratio (r).
Effect of anisotropy
Earing
Stretcher strains
Stretcher strains
➢ Stretcher strains: In case of low carbon steel sheet,
flame like patterns of depressions appear on the
surface and spread to the remaining areas due to
yield point elongation phenomenon.
➢ Deformation at yielding is non-uniform due to
interaction of interstitial atoms with dislocations.
➢ Sheet is given a small deformation (cold
reduction of 0.5 to 2%) by temper rolling or skin
pass rolling to eliminate stretcher strains.
Orange peel
Orange peel
Orange peel: Pronounced surface roughness
in the areas that have undergone appreciable
deformation.
-due to large grain size (grains tend to
deform independently of each other)
-can be reduced by using sheets with fine
grain size.
Redrawing methods
Advantages of reverse redrawing
• The metal is subjected to bending in the
opposite direction to its original bending
configuration. This results in strain
softening and lower forces.
• Because of the strain softening
(Bauschinger effect), the material is more
ductile and deeper cups can be drawn.
• Design and fabrication of blank holder is
easier and simpler.
