Sheet Metal Anal

Sheet Metal Forming Analysis
ver. 1
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Processes
Shearing Bending Shear Spinning Tube Drawing
Shearing / Blanking / Punching
Shearing / Blanking / Punching

First approximation
Fshear = s Area = s perimeter thickness

Better approximation
Fshear = 0.7 UTS Area
Bending
Bending analysis
As the punch descends, contact forces at the die produce bending moments near the punch, of large enough magnitude, to produce the required deformation.
Bending analysis
t rd b = width l rp punch
die
Note: punch + 2die = 180o

Bending analysis
Assume b >> t, so we have plane strain. First, analyze the strain in the sheet.
Strain in sheet
rp t 0 0 A A N.A.
etensile
l OA OA = = l OA
9
Strain in sheet
l = r
rp + t r p + etensile = t rp + 2 t rp + t r p 2 etensile = t rp + 2
t 2
10
Strain in sheet
etensile = t 2 t rp + 2
etensile
1 l = = ( from tensile test ) 2rp l 1+ t

11
Strain in sheet
The neutral axis actually moves about 5% to the compression side.
etensile =
1 rp 0.82 + 1.8 t
12
Punch radius due to true strain

r + t l final = ln p true = ln t linitial rp + 2 r +t p true = ln t rp + 2
13

We also know
1 failure (necking ) = ln 1 RA
RA = reduction in area in tensile test

r +t 1 p ln = ln r + t 1 RA p 2
14

t rp + = rp + t RA rp RA t 2
or
1 rp = t 1 2 RA
15
Check Elastic Contribution

Make sure you are plastic
eelastic
1 = < = etensile 2rp E 1+ t
yield
16
Perfectly plastic material

As bend progresses, plastic zone grows until we get a fully plastic material.
Mb yield Mb yield rp yield
17

Mb = r F = r A
yield t/2 t/2 yield t b
t t 2 Mb = 2 yield b 2 2
(2 sides, center of action of one side, stress, area of one side)
Mb =
yield bt 2
4
18
Elasticplastic material
There is usually some elasticity in the center, otherwise you would exceed the maximum elongation in the metal.
yield E t/2 yield a/2
yield
19
Moment produced by elastic region
M elastic a 2 a = 2 yield 2 b 2 3 2
(2 sides, center of action of triangle, max value, area of triangle)
M elastic =
yield ba 2
6
20
Moment produced by plastic region
M plastic = 2 yield a ta ta b + 4 2 2
(2 sides, stress, width, center of action of plastic region, thickness of plastic region)
M plastic =
yield b t 2 a 2
4
21
M b = M elastic + M plastic
Mb =
yield ba 2
6
+
2
yield b t 2 a 2
4
2
Mb =
yield b
12
3t a
)
22
Strain hardening material
= yield + ke
1 yield 1
2
yield k e yield
yield
Mb =
yield bt
4
+ M triangle section
23
yield
Strain hardening
1
M triangle section
1 t 2 t = 2 1 yield b 2 2 3 2
(2 sides, center of action of triangle, max stress, area of triangle)
M triangle section
(1 yield ) bt 2 =
6
24
Strain hardening
Mb =
Mb =
yield bt
4
(1 yield ) bt +
6
1 + 2 1 yield
yield bt
12
25
Contact and punch forces

Friction needs to be included
N N l 0 N N N N
F N
Mb N
26
Bending force
M0 = 0
l Mb = N cos
F = 0
F = 2 [N cos + N sin ]
if rp<<l and we can ignore the moment due to N
M b cos N= l
2M b 2 F = cos + sin cos l
]
27
Maximum bending force angle

As the punch moves down, the force goes through a maximum when
dF =0 d
and
d 2F < 0 (so its a maximum) 2 d
2M b dF =0= [ cos sin sin cos d l + cos cos sin sin ]

28
Maximum bending force angle

cos sin + sin cos = (cos sin )
2 2
sin 2 = cos 2
sin 2 = = tan 2 cos 2
Maximum force at
1 = tan 1 2
29
Bending force as function of

F increasing
max
30
Springback (wiping die)
31
Springback
Figure represents one-half of the geometry

32
Springback due to unloading

Springback is equivalent to a negative Mb, so that the total stress is zero, yet the internal stresses are are not.
(N.B. = radius of curvature at the neutral axis.)
M Myield EI
loading EI unloading permanent plastic deformation = 1/final elastic recovery = 1/elastic 1/

33
1/yield 1/final
1/bent
Springback fully plastic

yield elastic = 1.5 yield
+
yield plastic t/6 yield/2 t/3 yield t/6
34
elastic = -1.5 yield elastic

(elastic = 1.5 yield due to equal moments)
-yield
t/3
yield/2

final = bent - elastic
final
bent
elastic
bent bent = 1 final elastic

35

change in angle of sheet /2 bent /2 final
final bent = elastic

=
final bent
bent
elastic 1 = bent
36

noting that a line on the neutral axis remains constant
= a constant
hence
elastic bent = bent elastic
bent
elastic bent = = bent elastic

37

and
elastic
M b 12M b = = EI Ebt 3
Mb =
combining
yield bt 2
4
3 bent yield Et
38
bent
12 bent M b Ebt
3

For a bottoming die (bent = punch)
bent
t = rp + 2
t 12M b t 3 yield = rp + = rp + 3 2 Ebt 2 Et
punch
39
Springback elastic-plastic
Non-strain hardening, not fully plastic, bottoming die Total moment
t2 a 2 M b = yield b 4 12
Elastic region 2 yield 1 = bent Ea
40
2 2 4 bent yield b 3 yield t 2 Mb = 2 12 E
Unloading which produces an elastic stress moment of the same magnitude, would produce the curvature
elastic
M b 12 M b = = EI Ebt 3
41
Substituting into Mb
2 4 bent 3 b yield 2 3 yield t 12 E2
b Et 3 = 12 elastic
rearranging
elastic
2 3 yield 4 bent 3 yield = Et E 3t 3
42
bent elastic
from above
3 3 yield bent 4 bent 3 yield = 3 3 Et E t
bent bent = 1 final elastic

hence
yield bent yield bent bent 3 =1+ 4 Et Et final

43
from above
bent
hence
bent
yield bent = 3 Et
yield bent 4 Et
44
bent
t = rp + 2
yield t rp + 4 2 Et t rp + 2
3
punch
yield = 3 Et
45
Springback strain hardening

For a bottoming die, total moment
Mb =
yield bt
12
1 + 2 1 yield
Unloading which produces an elastic stress moment of the same magnitude, would produce the curvature
elastic
M b 12 M b = = EI Ebt 3
46

Substituting into M
yield bt
12
1 + 2 1 yield
yield
Et
3 b = Et 12 elastic
rearranging
elastic
2 1 1 + yield
47

from above
bent
combining
bent
bent yield
Et
2 1 1 + yield
48

bent
t = rp + 2
punch
t yield = rp + 2 Et
1 + 2 1 yield
49
Springback note
If punch does not bottom in die, then springback in the arms needs to be considered. For example, air bending
50
Compensation for springback

Overbending Coining
apply highly localized stress between punch nose and die surface
Stretch bending
sheet is in tension while being bent fill tubes with sand and stretch to prevent buckling and collapse
Heating
softens material, lowers flow stress, increases ductility
51
Bendability
Assess bendability (rp/t) as b (length of bend) increases
ductility of sheet metal decreases
uniaxial to biaxial stress state (plane strain)
minimum rp increases
Anisotropy and inclusions are important Edge conditions

e.g., roughness from shearing can introduce cracks
52
Bendability
53
Bending Ex. 1-1

Bend a plate of steel to 90 degrees, using a bottoming punch and die set. Estimate the punch and die angles Determine Fmax
54
Bending Ex. 1-2

E = 29 x 106 psi yield = 50,000 psi = 80,000 psi @ e =0.4 t = 0.05 inch rp = 0.15 inch b = 1 inch = 0.1 2l = 2 inch maximum elongation = 40%
55
Bending Ex. 1-3

From
etensile
1 1 = = = 0.143 < 0.40 2rp 2 0.15 1+ 1+ 0.05 t
so the max strain is less than the max elongation also, check to see if we are plastic:
eelastic =
yield
E
50,000 = = 0.17% vs. 14% 29,000,000

56
Bending Ex. 1-4

Now we need the stress to go with the strain, assume a strain hardening metal
= yield + ke
solving for k
80,000 50,000 k= = 75,320 psi / in / in 0.4 0.0017 solving
= 50,000 + 75,320 e
substituting the strain
1 = 50,000 + 75,320 0.143 = 60,771 psi

57
Bending Ex. 1-5

Mb =
yield bt 2
12
2 1 1 + yield
substituting data
50,000 1 0.052 2 60,771 Mb = 1 + = 35.74 in lbf 50,000 12
58
Bending Ex. 1-6

Now, calculate max force
1 1 1 = tan = tan 1 0.1 = 2.86 2 2
2M b 2 F = cos + sin cos l
]
]
2 35.74 F = cos2 2.86 + 0.1 sin 2.86 cos 2.86 = 71.7 lbf 1
59
Bending Ex. 1-7

Now for the punch and die angles
t yield = rp + 2 Et 1 + 2 1 yield
punch
punch
0.05 50,000 2 60,771 1 + = 0.15 + = 0.021 6 2 29 10 0.05 50,000
60
Bending Ex. 1-8

punch
90 = = = 88.1 (1 + 0.021) 1 + punch
final
die
1 1 = 180 punch = (180 88.1) = 45.95 2 2
61
Shear Spinning
62
Shearing geometry
t original blank roller t flange c /2 mandrel
after Kalpakcioglu (1961)
tc
tc = t sin
tailstock
63
Ideal process
Flange Dt Roller f /2 R=Dc/2 dR /2
64
Shear in ideal process

if the flange is straight, i.e., /2 = 90o /2 d t
thickness cot axial distance moved (d) 2 = = thickness thickness

for the more general case
= cot
cot
2
65
Energy per unit volume, u

For a plane strain problem
cot
cot
u=
d = d
0
66
Strain
From distortion energy theory
2 2 2 2 (1 2 ) + ( 2 3 ) + ( 3 1 ) = 3
for plane strain 1 = -3, and 2 =0
1 2
2 2 2 = (1 0) + (0 1 ) + (1 1 ) 3
from Mohrs circle
1 2 2
2 = 1 3
hence
= 3
67
Strain
Substituting for shear strain,
1 = = cot cot 2 2 3 3
68
Power
d (vol ) P =u dt
where
dR d (vol ) = 2tR = 2tRNf sin 2 dt dt

N = rev/time, f = feed rate/rev
69
Power, Torque, Force

Power = tfNDc sin
Torque = Power
d
0
1 = tfDc sin d 2 2
Torque Ftangential = = tf sin d radius 2
70
Perfectly plastic metal

u = yield
and
2 = 90
Power = tfNDc sin

Power = tfNDc sin
yield
1 3 cot
yield
Power =
1 3
tfNDc yield cos
2
71

Similarly
Torque =
1 2 3
tfDc yield cos 1 3
Ftangential =
tf yield cos
72
Tube Drawing
73
Plane strain / Slab analysis

xa 1 + B* = 2 flow B*
Fixed mandrel (plane) Moving mandrel (plane and slab)
t 1 f ti
B*

2 2 B tan
*
2 B tan
*
Fixed mandrel (slab)
B*
tan
Moving mandrel with friction towards exit, takes into account motion between mandrel and tube (B may be negative) (plane)
die mandrel B tan

*
74
Summary
Analyses for
Shearing Bending Shear Spinning Tube Drawing
75
76

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Sheet Metal Forming Analysis

Shearing / Blanking / Punching

Shearing / Blanking / Punching

Fshear = s Area = s perimeter thickness

Fshear = 0.7 UTS Area

Note: punch + 2die = 180o

1 l = = ( from tensile test ) 2rp l 1+ t

Punch radius due to true strain

Punch radius due to true strain

RA = reduction in area in tensile test

Punch radius due to true strain

Check Elastic Contribution

1 = < = etensile 2rp E 1+ t

Perfectly plastic material

Perfectly plastic material

(2 sides, center of action of one side, stress, area of one side)

(2 sides, center of action of triangle, max value, area of triangle)

Strain hardening material

(2 sides, center of action of triangle, max stress, area of triangle)

Contact and punch forces

if rp<<l and we can ignore the moment due to N

2M b 2 F = cos + sin cos l

Maximum bending force angle

d 2F < 0 (so its a maximum) 2 d

2M b dF =0= [ cos sin sin cos d l + cos cos sin sin ]

Maximum bending force angle

Bending force as function of

Springback (wiping die)

Figure represents one-half of the geometry

Springback due to unloading

loading EI unloading permanent plastic deformation = 1/final elastic recovery = 1/elastic 1/

Springback fully plastic

elastic = -1.5 yield elastic

Springback fully plastic

bent bent = 1 final elastic

Springback fully plastic

final bent = elastic

Springback fully plastic

elastic bent = bent elastic

elastic bent = = bent elastic

Springback fully plastic

Springback fully plastic

2 3 yield 4 bent 3 yield = Et E 3t 3

bent bent = 1 final elastic

yield bent yield bent bent 3 =1+ 4 Et Et final

elastic bent = = bent elastic

Springback strain hardening

Springback strain hardening

Springback strain hardening

elastic bent = = bent elastic

Springback strain hardening

Compensation for springback

Anisotropy and inclusions are important Edge conditions

Bending Ex. 1-1

Bending Ex. 1-2

Bending Ex. 1-3

1 1 = = = 0.143 < 0.40 2rp 2 0.15 1+ 1+ 0.05 t

50,000 = = 0.17% vs. 14% 29,000,000

Bending Ex. 1-4

80,000 50,000 k= = 75,320 psi / in / in 0.4 0.0017 solving

1 = 50,000 + 75,320 0.143 = 60,771 psi

Bending Ex. 1-5

50,000 1 0.052 2 60,771 Mb = 1 + = 35.74 in lbf 50,000 12