INSPIRE FORM V2018 - CH1: INTRODUCTION TO FORMING PROCESS

© 2018 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire Form, v2018

CHAPTER 1 - INTRODUCTION TO FORMING PROCESS

1) Introduction to Forming Process

• Introduction to forming process
• Sheet metal forming process types
• Defects in sheet metal forming
• Sheet Material Behavior
• Questions & Answers

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Inspire Form, v2018

INTRODUCTION TO FORMING PROCESS

• Sheet metal forming process transform the flat sheet blank to desired final product in one
or more stages of forming operations depending on part complexity.

Transfer die forming Progressive die forming

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Inspire Form, v2018

SHEET METAL FORMING PROCESS TYPES: DEEP DRAWING FORMING

• Deep drawing forming

• The sheet metal is held against the die by the blank

holder. While it is formed against the die by the punch.

• The blank holder applies predefined force to control

material flow into the die cavity.

• The sheet metal undergoes relatively small change in the

thickness.

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Inspire Form, v2018

SHEET METAL FORMING PROCESS TYPES: DEEP DRAWING FORMING

• Single Action Deep drawing
• Bottom die set includes blank holder/Binder and bottom die.

• Top die comes down and clamps the sheet against blank holder/Binder.

• Top die and blank holder/binder holds sheet moves down and forms the sheet against bottom die.

• Top die retracts with binder following taking the part up ready for transfer.

d) Retracted position

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 © 2018 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire Form, v2018

SHEET METAL FORMING PROCESS TYPES: DEEP DRAWING FORMING

• Double Action Deep drawing
• Top die set includes blank holder/Binder and top die.

• Blank holder /Binder comes down and clamps the sheet against bottom die.

• Top die moves down and forms the sheet against bottom die.

• Top die retracts followed by blank holder/binder and part is ready for transfer.

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 © 2018 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire Form, v2018

SHEET METAL FORMING PROCESS TYPES: DEEP DRAWING FORMING

• Double Action Deep drawing
• Sheet metal can be drawn in multiple stages to get to the finished part.

Redrawing Reverse Drawing

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Inspire Form, v2018

SHEET METAL FORMING PROCESS TYPES: STRETCH FORMING

• Stretch Forming
• Surface area of the blank is enlarged by stretching or stretch-drawing of the punch into die cavity to
form the component.

• Material from the flange is locked to flow.

• The ability of the material to redistribute stresses by work hardening is critical in stretch forming, i.e.
n-value.

• Combination of Low Yield plus High Tensile Strength is optimal for stretched panels

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Inspire Form, v2018

SHEET METAL FORMING PROCESS TYPES: BENDING

• Bending
• Sheet Metal usually flat is subject to a curvature change over a finite radius along a straight line.

• Process Types

• Brake bending: Air, V, U, rotary bending etc.

• Bending in tools: Wiping die bending, Roll bending, Bead forming, Flanging (shrink, stretch and
hole), Hemming, Tube bending

Air Bending V Bending Wipe Bending

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Inspire Form, v2018

SHEET METAL FORMING PROCESS TYPES: FLANGING

• Flanging - Bending of sheet metal not on a straight line

Stretch Flange Straight Flange

Straight Flange All other Flange types

Shrink Flange
Reverse Flange

Jogged Flange Hole Flange

Hole Flanging
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 © 2018 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire Form, v2018

DEFECTS IN SHEET METAL FORMING

• Splits - Excessive stretch deformation of material beyond its limits

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 © 2018 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire Form, v2018

DEFECTS IN SHEET METAL FORMING

• Wrinkling – Excessive compressive deformation of material beyond its limits

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 © 2018 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire Form, v2018

DEFECTS IN SHEET METAL FORMING

• Springback – Elastic recovery of the sheet metal after part is taken out of the dies.

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 © 2018 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire Form, v2018

DEFECTS IN SHEET METAL FORMING – SURFACE DEFECTS

• Fall in, Low spots - Not following the die shape - Insufficient stretch, local and immediate
transitions in stress states.

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Inspire Form, v2018

DEFECTS IN SHEET METAL FORMING – SURFACE DEFECTS

• Bad ‘Strike’, multiple contacts out of sync, Bow Waves, Kinks

• Kinks are a cosmetic defect due to the metal sheet scrolling on the edges which can reproduce a style
line/shape

Punch Punch

Sheetmetal

Kinks

Punch
Punch

Sheetmetal

15 Kinks
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DEFECTS IN SHEET METAL FORMING – SURFACE DEFECTS

• Skid lines - Bending and stretch with high contact pressure

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DEFECTS IN SHEET METAL FORMING – LOOSE METAL

• Loose metal - Sheet metal not sufficiently stretched resulting in loose metal that snaps
upon applying force and not confirming shape.

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Inspire Form, v2018

SHEET MATERIAL BEHAVIOR

• Sheet Material Behavior - Tensile test

Force Vs Deflection Stress Vs Strain curve Fit to standard equations

sT = KeT n or sT = s o + KeT n
s = K (e o + e )n
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Inspire Form, v2018

SHEET MATERIAL BEHAVIOR

• Sheet Material Behavior - Anisotropy

Grain
oriented
along
rolling

Rolling process causes Plastic strain ratio R from Quantify anisotropy in sheet
orthotropy in sheet metal Tensile test metal

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 © 2018 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire Form, v2018

SHEET MATERIAL BEHAVIOR

• Sheet Material Behavior - Forming Limit diagram

Stretch forming

Deep drawing
• A plot of Major and Minor strain • Limit curve obtained from • Captures all deformation
experiments gives the forming limit of modes
• Location on the plot gives material beyond which it fails.
information of mode of
deformation
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 © 2018 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Inspire Form, v2018

QUESTIONS & ANSWERS

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