Dr. M. Medraj Mech. Eng. Dept. - Concordia University Mech 421/6511 lecture 9/2. Die Radius:. and Friction Zone
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1 Outline Deep Drawing Deep drawing analysis Other Sheet metalwrking peratins Frmability f Sheet Metal - cupping test - bulge test - frming-limit diagram - tensin tests nrmal anistrpy planar anistrpy Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/1 Sheet metal frming t make cup-shaped, bx-shaped, r ther cmplex-curved, hllw-shaped parts Sheet metal blank is psitined ver die cavity and then punch pushes metal int pening Steps: Initial cntact Bending Straightening Frictin and cmpressin Final shape Deep Drawing Prducts: beverage cans, ammunitin shells, autmbile bdy panels Deep drawing was patented in Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/2 Deep Drawing Deep Drawing: - Variables and Defects Significant Variables Prperties f sheet metal Rati f blank diameter t punch diameter Sheet thickness Clearance between the punch and the die Punch and die and crner radii Blankhlder frce Frictin and lubricatin at the tl/wrkpiece interface Speedf the punch Die Radius:. and Frictin Zne Punch Radius:.. and Frictin Zne Cup Flange: and Frictin Zne Cup Bttm: -. Strain - N Frictin Cup Wall: -.. Zne - Plane Strain -. Frictin Failure results frm thinning f the cup wall Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/3 Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/4
2 Deep Drawing: - Variables and Defects During drawing, when the blank mves int the die, cmpressive circumferential stresses are induced in the flange This causes flange t wrinkle Deep Drawing: - Variables and Defects Lw carbn steels exhibit this behavir This prduces lueder s bands (stretch strain marks) These marks can be eliminated by reducing thickness f sheet frm 0.5 % t 1.5 % by cld rlling prcess Eg: try frcing a circular sheet f paper int a drinking glass Die radius t small Punch radius t small Yield-pint elngatin in a sheet-metal specimen Lueder s bands in a lw-carbn steel sheet. Grain size: mechanical prperties and surface appearance are affected by the grain size. The carser the grain the rugher the appearance. (Orange Peeling defect) Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/5 Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/6 Mst easily defined fr cylindrical shape: Analysis f Drawing Measure f Drawing: D Drawing rati: Dp Db Dp - Reductin r = feasible if r < 0.5 D b DR = feasible if DR < 2 Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/7 b Crude measures f the severity f a deep drawing peratin Drawing Frces: ( ) Db F = πd 0. 7 pt TS Max at 1/3 length Dp Hlding Frce: 2 [ D ( D + 2.2t 2R ) ] 2 F h = 0.015Yπ b p + d Analysis f Drawing Clearance in Drawing: c = 1.1 t where t = stck thickness In ther wrds, clearance = abut 10% greater than stck thickness Thickness-t-Diameter Rati: Thickness-t-diameter rati = t/d b As t/d b decreases, tendency fr. increases Desirable fr t/d b rati t be greater than 1% Blank Size Determinatin: Fr final dimensins f drawn shape t be crrect, starting blank diameter D b must be right Slve fr D b by setting starting sheet metal blank vlume = final prduct vlume T facilitate calculatin, assume negligible thinning f part wall Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/8
3 Shapes ther than Cylindrical Cups Other Sheet Metal Frming n Presses Square r rectangular bxes (as in sinks), Stepped cups, Cnes, Cups with spherical rather than flat bases, Irregular curved frms (as in autmbile bdy panels) Very imprtant cmmercial prcess. Each f these shapes presents its wn unique technical prblems in drawing Makes wall thickness f cylindrical cup mre unifrm Examples: beverage cans and artillery shells Used t create indentatins in sheet, such as raised (r indented) lettering r strengthening ribs.. Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/9 Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/10 Other Sheet Metal Frming n Presses Lw tling cst Frm blck can be made f wd, plastic, r ther materials that are easy t shape Rubber pad can be used with different frm blcks Prcess is attractive in small quantity prductin Guerin Prcess Methds fr Reducing the Diameter f Drawn Cups Reverse Redrawing Cnventinal Redrawing.. Redrawing A methd t reduce the diameter f drawn cup Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/11 Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/12
4 Hemming Prcess Steps in Manufacturing an Aluminum Can The edge f the sheet is flded ver itself This increases stiffness f the part This methd is nw used in the autmtive industry t jin an uter part and an inner part. The metal strip is bent in stages Defects during hemming: Springback, Fractures and Wrinkels in the flange Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/13 Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/14 Frmability f Sheet Metals Bulge Test Erichsen test A cupping test (Erichsen and Olsen tests) t determine the frmability f sheet metals Erichsen number The greater the value f d the greater is the frmability Earliest tests develped Simple t perfrm. indicatr f frmability D nt simulate exact cnditins f actual peratins, WHY? Bulge-test results n steel sheets f varius widths. The specimen farthest left is subjected t, basically, simple tensin. The specimen farthest right is subjected t equal biaxial stretching It has been used extensively t simulate sheet frming peratins Hydraulic pressure is used instead f punch stretch frming withut frictin it is used t btain effective-stress vs. effective-strain curves fr biaxial lading under frictinless cnditins Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/15 Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/16
5 Majr Strain and Minr Strain Frming Limit Diagrams The defrmatin f the grid pattern and the tearing f sheet metal during frming. The majr and minr axes f the circles are used t determine the crdinates n the frming-limit diagram. During stretching in sheet metal, Vlume cnstant ε l + ε w + ε t = 0 Majr strain always larger than minr strain Majr strain. than 0 Minr strain can be either psitive, negative r zer Plane strain Minr strain is 0 ε l + ε w + ε t = 0, thus ε l + ε t = 0 Althugh the majr strain is always psitive (stretching), the minr strain may be either psitive r negative r zer Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/17 Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/18 Frming-limit Diagrams (FLD) Nrmal Anistrpy Mre a research/develpment tl than a practical (quick) test Time cnsuming t perfrm Represents. frming peratins reasnably well Tensin Tests The mst basic and cmmn test used t evaluate frmability It determines imprtant prperties f the sheet metal such as: - ttal elngatin f the sheet specimen at fracture - strain hardening expnent - the planar anistrpy, and - the nrmal anistrpy Nrmal anistrpy: R = ε w / ε t Remember: ε l + ε w + ε t = 0 Simple tensin, R =1.0 Determines thinning behavir f sheet metals during stretching; imprtant in deep-drawing peratins Tensile tests determine nrmal anistrpy Strains n a tensile-test specimen remved frm a piece f sheet metal. These strains are used in determining the nrmal and planar anistrpy f the sheet metal. Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/19 Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/20
6 Average Nrmal Anistrpy Average Nrmal Anistrpy Vs Limiting Drawing Rati R avg = (R 0 + 2R 45 +R 90 )/4 Nrmal anistrpy (R) R 0 R 45 The relatinship between average nrmal anistrpy and the limiting drawing rati fr varius sheet metals Rlling Directin R 90 Limiting Drawing Rati (LDR) = D 0 /D p Where, D 0 : Maximum Blank diameter D p : Punch Diameter Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/21 Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/22 Average Nrmal Anistrpy, R avg Typical Range f Average Nrmal Anistrpy, R avg, fr Varius Sheet Metals R avg Zinc allys Ht-rlled steel Cld-rlled rimmed steel Cld-rlled aluminum-killed steel Aluminum allys Cpper and brass Titanium allys (a) Stainless steels High-strength lw-ally steels Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/23 Nrmal anistrpy (R) Rlling Directin Planar Anistrpy (Earing Tendency) R 0 R 90 R 45 Planar anistrpy causes ears t frm in drawn cups When R=0, n ears frm The height f the ears increases as R increases Number f ears: 4, 6, r 8 fr better deep drawability: R avg and R.. and. affect these values. Planar Anistrpy R = (R 0-2R 45 +R 90 )/2 Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/24
7 Earing and Planar Anistrpy Effect f Planar Anistrpy n Earing R R R<0 R R 2 R>0 R + R R = 2R R = ε w / ε t Next time: Cntinue Sheet Metal Frming h h Rlling Directin Rlling Directin Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/25 Dr. M. Medraj Mech. Eng. Dept. - Cncrdia University Mech 421/6511 lecture 9/26
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