Journal of Materials Processing Technology 94 (1999) 167174

Finite-element analysis and design in the combined precision forming

of bending and coining with experimental measurement
Sang-Kyu Byuna, Byung-Woo Huhb, Beom-Soo Kanga,*
a

Department of Aerospace Engineering, ERC for Net-Shape and Die manufacturing, Pusan National University, Pusan 609-735, South Korea
b
LG Production Technology Research Center, Changwon, South Korea
Received 23 February 1998

Abstract
Process design is one of the most important elds in metal forming. A multi-operation process sequence for the forming of a precision
mechanical component, an aperture, a critical component in the electronic guns of TV tube, is studied here for seeking improvement of the
conventional process. The process has two forming characteristics; beading and bending of precision stamping; and coining of bulk
forming. The multi-operation forming process is analyzed and designed by the nite-element method, and the results are conrmed by a
series of experimental formings with the aid of precision measurement. The process consists of 16 operations, amongst which two critical
operations, a beading and bending, and a coining, are investigated to determine forming defects, and to improve the process design. The
design by the nite-element method considers the elastic shrinking of the die and the punch, which enables compensation in the industrial
design of the die and punch set. This design system, established by nite-element analysis as well as by precision measurement, can be
applied in the development of a new aperture component. # 1999 Elsevier Science S.A. All rights reserved.
Keywords: Process design; Aperture; Progressive dies; Beading; Bending; Piercing; Coining; Spring back

1. Introduction
The precision sheet forming process has been used in
various industrial areas because of its efciency in mass
production and in the stability of quality. Presently it is used
widely with advanced technology such as with progressive
dies, transfer presses and so on.
Electronic products become smaller and need more functions in them [1]. High precision and productivity are
required for a component itself [2]. A press-forming process
is designed by considering the product shape, the materials,
the lubricant, and the press. Thus high-quality products can
be manufactured if and only if these conditions are considered in harmony. Especially in process design, there are
many factors, such as the determination of processes, the
design of dies, and the preform shape. It is important to carry
out process design efciently in the development of complex-shaped products which should be formed through
multi-stage processes [3,4].
During the development of a product, much waste trialand-error can occur because of lack of design experience,
*Corresponding author. Fax: +82-51-513-3760.

which causes an enormous waste of time and cost. To correct

these defects, traditional analytic methods have been used
such as the upper-bound technique and the slip-line method
[5,6]. However, it is difcult to secure accurate and detailed
results using these conventional methods, and thus they have
been replaced with the FEM (nite-element method) [712].
The combination of the FEM analysis and the experiences of
experts can achieve a more effective design in precision
forming with multi-stage operations.
An aperture is a key component of an electronic gun used
in a CRT. This study focuses on the process analysis by the
nite-element method of a sequence composed of 16 operations with progressive dies. Some defects are discovered
from the analysis of the deformation of the material, of the
spring-back effect, and of the distribution of thickness, stress
and strain. They are compared with precision measurement
data of experimental aperture samples.
2. Modeling for FEM analysis
The material of the workpiece for aperture forming is
I106S, which is a type of carbon steel, its thickness being

0924-0136/99/$ see front matter # 1999 Elsevier Science S.A. All rights reserved.
PII: S 0 9 2 4 - 0 1 3 6 ( 9 9 ) 0 0 0 9 5 - 3

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Fig. 1. Schematic description of the process sequence and constraints by the strip for the forming of an aperture (deformation occurs in the gray zones).

0.33 mm. Elasto-plastic FEM is used to investigate the

spring-back effect at the end of each process. The non-linear
equations involved are solved by the NewtonRaphson
method. A quarter of the workpiece is analyzed in the
numerical method due to symmetry of the geometry and
boundary conditions. The friction factor at the dieworkpiece interface is selected as 0.05. The elastic modulus is
obtained as 131.4 kN/mm2, and the yield stress as 330 kN/
mm2, from a series of experiments.
The anisotropy effect appears to be of importance in sheet
forming, and can be considered by the ratio of the plastic
deformation (the Lankford value) R, the planar anisotropy
coefcient
R, and the perpendicular anisotropy coefcient
 These coefcients are measured through material tests
R.
and are found as follows.
1. The ratio of plastic deformation, R:
R

w lnwf =wo
;

t
lntf =to

where wf means the nal width, wo the original width, tf

the nal thickness, and to the original thickness. The
measured values for each of the directions 08, 458, and
908 to the rolling direction are provided: R00.905;
R451.008; R901.007.
2. The planar anisotropy coefficient,
R:

R

R0 R90
R45 0:052:
2


3. The perpendicular anisotropy coefficient, R:
 R0 2R45 R90 0:982:
R
4
The phenomenon of earing in sheet metal forming is
assessed in view of the value of the planar anisotropy
coefcient. Here the value is close to zero. The value of
0.982 of the perpendicular anisotropy coefcient means that
the material deforms as an isotropic material. Based on the
experimental results, the anisotropy effect is neglected in the
numerical analysis.
For the coining operation, the magnitude of the elastic
contraction of the punches is to be analyzed. The material
of the punch is GA20, the elastic constant of which is
588 kN/mm2, and Poisson's ratio is 0.3.

3. Forming processes and boundary conditions

The operations of beading and bending, and the rst
coining are analyzed by the FEM, since these operations
have severe deformation, and have serious effect to the
following operations. Fig. 1 shows the planar congurations
of the workpiece during the main processes and the constraints by the strip. The initial billet is deformed without
variation in its thickness during the beading and bending
process. Then pre-holes of 1.0 mm diameter are drilled
through the rst piercing operation to help in the second
piercing and to control the thickness of the coining part by
the lling of the hole again in later processes.
It is difcult to determine the effects of the piercing of the
holes by the FEM, and the holes are replaced by inactive
elements that are removed after forming. The thickness of
the inner part of the circular bead is reduced during the
operation of the rst coining process. Originally the punch
and die overlapped each other when the ywheel of the press
reached its bottom dead point. They deform elastically by
the reaction force from the workpiece in operation, hence it
is important to predict the magnitude of elastic contraction
accurately.
The central part in the bead is thinned by the punch, which
has small circular projecting parts. Then the dimensions of
the main parts are formed precisely in later sizing operations, the forming operations ending at the second piercing
and the following parting process. Fig. 2 shows planar and
sectional congurations of the product and the control
volume involved in the numerical analysis.

Fig. 2. Planar and sectional configurations and the control volume used in
the analysis.

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169

Fig. 4. Final deformation of the cross-section after the B&B operation.

Fig. 3. Initial mesh system and die setup for the beading and bending
operation.

4. Beading and bending process

The rst main operation, beading and bending, affects the
precision of the complete components because it makes the

forming contour of the parts. The numerical analysis provides comparisons with the experimental measurement of
the samples to increase the reliability of the study. Comparisons are made of the thickness distribution and the length
change along two critical lines, of the height of the bead and
the bent parts, and of the spring-back pattern after releasing
of the punch and dies.
The die set-up and initial mesh system for the operation
are shown in Fig. 3, where one quarter of the whole body is
displayed due to its symmetry condition. The die set consists
of a punch, a lower die, and a pad that pushes up the billet to
move it to the next process after the completion of the
current process.

Fig. 5. Sectional deformations along the PP line caused by the spring-back effect: (a) the spring-backed configuration of section PP; (b) numerical
comparisons of the primary dimensions (units: mm).

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The mesh system in the bead is generated in detail

because it is complex and severe deformation occurs in
later processes at this part. Fig. 4 shows the mesh deformation when the punch falls to its lowest point.
The spring-back effect is calculated after forming simulation, that along section PP being given in Fig. 2, the height
of the beads decreasing whilst their thickness and length
increase. The numerical data are summarized in Fig. 5(b),
which compares the data for the lowest die contact (LDC)
with the data after counting the spring-back effect.
The sectional conguration from the sample test is shown
in Fig. 6 compared with the results of the FEM analysis.

Fig. 7. Sectional configuration for line CC after spring back (units: mm).

Several differences are found between them such that a

convex pattern in the upper surface and the lifting of the
lower surface of the bead do not coincide with the results of
the analysis.
The spring-back recovery along section CC is shown in
Fig. 7. The ange part rises and the cross-sectional length
appears to be extended. The height of the bead and the bent
parts and the thickness increase uniformly. The trends agree
with those of the experiments. A small twist and a raised part
are found at the edge of the bending line (see Fig. 8)
conrmed by the results of the tests. Fig. 9 shows a difference of about 0.01 mm between the two edges of the line.
Also, some differences between the FEM analysis and the
experimental results are detected along section PP. This
may be due to dimension errors between the design and the
real dies as a result of lapping (see Fig. 10). This can affect
the material ow pattern during the deformation. Thus, the
dimensions of the real dies should be examined in detail. The
effect of lubrication is also to be investigated again for more
accurate result. Fig. 11 shows the deformed shape of the
workpiece along with the effective stress distribution.
5. The coining process

Fig. 6. Sectional configuration after spring back from the analysis and
experiment along line PP: (a) from the analysis; (b) upper surface
measured by Surf. Com.; (c) lower surface measured by Surf. Com.

The workpiece is pierced after beading and bending.

Piercing is expressed by removing the elements at these
points, the deformation behavior of the holes being observed
in later operations. In the coining process, the punch is down
lower than in the foregoing process, and reduces the thickness of the inner part of bead from 0.33 to 0.1 mm. The bead,
suffering spring back in the beading and bending operation,
is formed again to the desired dimension simultaneously.
The cross-sectional shape and dimensions of the dies are
shown in Fig. 12 at their closed state. The central parts of the
die and punch that effect coining overlap each other. Therefore, the magnitude of H1 and H2 in Fig. 5 cannot be

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171

Fig. 8. Twisted parts at the end of the bending line.

Fig. 9. Deformation of section AA by spring back (scale: mm): (a) from

the analysis; (b) from the experiment.

Fig. 10. Points of expected lapping during the manufacturing of the dies.

decided initially, and they are reduced due to the reaction

forces of the workpiece during the process.

Fig. 11. Three-dimensional configuration after the B&B operation (units:

MPa).

Elastic analysis is carried out for dies to obtain accurate

amount of the contraction during forming. Initially, the dies
are counted as rigid bodies, then the die loads and strokes are
found by simulation at which the thickness of the coined part
is 0.1 mm after spring back. The maximum loads are
2000 kgf for the punch and 2200 kgf for the die (see
Fig. 13). With the maximum die loads, the elastic deformations of the die and punch are obtained by an FEM program.
It is known that the magnitude of contraction of the punch is
26.4 mm and of the die is 54.6 mm, the shape of the elastic
deformation being shown in Fig. 14. Fig. 15 shows the
deformation of the workpiece at the lowest position of
the punch, the stroke of which is found by the elastic
analysis.
The spring-back recovery after removing of dies from
the workpiece is compared with the experimental result.

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Fig. 12. Sectional configuration and dimensions along line PP (units:

mm).

The height of the bent part increases due to the elastic

recovery. Fig. 16 shows the spring-backed outline along
section PP. The upper surface of the coined parts shows
a concave pattern in the simulation, whilst at from the
experiment. The edge-rise trend around the pre-piercing
hole in the simulation does not coincide with the
experimental result, in which the part deforms with a
concave pattern. The change of thickness in the bent part
is not found along section CC but the height increases
(see Fig. 17). The ange part rises a little during the process,
but goes down by the spring-back effect. The numerical
results for section CC coincides with those of the experiment. Fig. 18 shows the contour of line AA in the simulation, the difference of the heights of the central and the
edge part being found to be reduced from 0.0715 to
0.0521 mm (see Fig. 9(a)). The central hole, which is shown
as G in the gure, deforms more severely than the right hole
shown as B in Fig. 19.

Fig. 13. History of the loads for the punch and die during the first coining operation: (a) punch load; (b) die load; (c) punch strokes correspond to the step
number.

S.-K. Byun et al. / Journal of Materials Processing Technology 94 (1999) 167174

173

Fig. 14. Shrinking of (a) the punch and (b) the die occurring under the
reaction load.

Fig. 16. Sectional configuration after spring back from the analysis and
experiment along line PP: (a) from the analysis; (b) upper surface
measured by Surf. Com.; (c) lower surface measured by Surf. Com.

6. Concluding remarks

Fig. 15. Final deformed cross-sectional configuration after the first

coining operation.

Finite-element analysis has been carried out for the

analysis of multi-stage cold press forming to produce an
aperture for electronic guns. Here two forming operations
are selected for numerical analysis and experimental conrmation amongst 16 operations, being beading and bending, and coining, since these two operations have a great
effect on the product quality.

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S.-K. Byun et al. / Journal of Materials Processing Technology 94 (1999) 167174

Fig. 17. Sectional configuration for line CC after spring back (units:
mm).

lished for application to precision forming with slight

modication.
The full three-dimensional simulation capability of the
program is adopted for more accurate results. This trial
might be the rst systematic application of the commercial
package to the precision forming of an aperture, and this
study can give technological impact to related industries in
the eld of analysis and design in precision forming by the
nite-element method.
Acknowledgements
This work has been supported by the Engineering
Research Center for Net-Shape and Die Manufacturing of
Pusan National University, and LG.

Fig. 18. Deformation of section AA by spring back (units: mm).

Fig. 19. Deformation of the pre-holes during the coining operation (units:
mm).

In view of the analysis and design result derived from the

numerical approach and experimental conrmation, the
processes of bending and coining are investigated thoroughly for the purpose of improvement of conventional
operations. The FEM analysis gives preliminary information
on the process design that is checked by a series of experiments.
The approach seeks to obtain a systematic design procedure in the forming of the precision component using a
commercial nite-element program with the aid of precision
experimental conrmation. Even though there are several
differences between the nite-element simulations and the
experimental results, a systematic approach can be estab-

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