I.

Bases para el análisis de procesos de conformado

Introducción al comportamiento
plástico de chapas

(Introduction to Plasticity of Metal Sheets)

Contents

Introduction
Sheet forming operations
Bending, deep drawing, stamping...

Plasticity of metal sheets

Basic relationships

Modes of sheet deformation

Constitutive models
INTRODUCTION
An important part of industrial metal production is made up of manufacturing of
sheets by cold or hot rolling.

Examples of products made of Advantages of sheet metal

sheet metal: products:

Car bodies

Building elements 
Mechanical strength

Aircraft fuselages 
High strength / weight ratio

Appliance coatings Buenas propiedades porque la chapa se ha

Canning and beverage fabricado or laminación en frio. Al someterlo a
deformacion plastica se consiguen buenas
containers propiedades mecanicas

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SHEET FORMING OPERATIONS
Bending (plegado)
All sheet-forming operations involve some bending. Often it is a major
feature. Springback occurs after the bending forces are removed and the
material contains residual stresses. If the bend radius is too sharp, there
may be tensile failure on the outside of the bend or buckling on the
inside.

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Deep drawing (embutición)
Sheet forming processes may be roughly classified by the state of stress. At
one end of the spectrum is the deep drawing of flat-bottom cups. In this
case, one of the principal stresses in the flange is tensile and the other
is compressive. There is little thinning, but wrinkling is of concern.

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Stamping (estampación)
At the other end of the spectrum are processes, usually called stamping, in
which both of the principal stresses are tensile. Thinning must occur.
Failures occur by the formation of a sharp local neck (localised necking). Estriccion
localizada

Operations called stamping, pressing,

and sometines drawing involve
clamping a sheet at its edges and
forcing it into a die cavity with a punch.
The sheet is stretched rather than
squeezed between the tools.

In some cases there is a

die, which reverses the
movement of material
after it is stretched over
the punch.

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Sheet forming operations
Flanging (rebordeado) Stretching (estirado)

Hydroforming

Spinning (repujado), roll forming (curvado con rodillos),

tube bending (doblado de tubos), etc.
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Incremental sheet forming
Incremental Sheet Forming (ISF) is a new sheet metal forming process with
a high potential economic payoff for rapid prototyping applications and for
medium/small quantity production.
Single-Point Incremental
Forming (SPIF) is the
simplest ISF process. It
consists on an hemispherical
forming tool that follows
progressively a pre-establish
trajectory, deforming a sheet
blank into a final component,
without the use of a forming
die.

Front section scale 1/8 of a Prototype of AIRBUS pylon

Medical Applications [Duflou et al., 2006] & Shinkansen (Bullet Train) Saint-Eloi, Toulouse (France)
[Amino Co. Ltd., Japan] [Penalva et al, 2011] 8
[Tanaka et al.,2005]
PLASTICITY OF METAL SHEETS
Sheet forming differs from bulk forming in several respects. In sheet forming,
tension predominates, whereas bulk forming operations are predominately
compressive. In sheet forming operations at least one of the surfaces is free
from contact with the tools.

Hypothesis:
1.Elastic strains << Plastic strains:

2.Plane strain (PS)

Volume conservation

3.Monotonous (no unloading) and proportional process (principal

stress/strain axes remain fixed). The following parameters can be defined:

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Basic relationships

(4 unknowns)

Hypothesis 3

Levy-Mises flow rule: (3 equations):

; with

Yield criterion (1 equation):

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Basic relationships
Effective stress and strain:

Relationship between the parameters α and β:

Flow rule

Forces per unit of width:

Sheet thickness:

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MODES OF SHEET DEFORMATION
Blank
sheet
previously
etched
with a grid
of circles:

Principal strains in a deformed circle:

Representation in a diagram of principal strains (ε1 versus ε2):

outer
sheet
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surface
Range of strain paths β
ε1 is the major strain and ε2 is the minor
strain:

ε1 ≥ ε2 → β≤1

It is not possible to form a sheet

without tensile tension:

σ1 = 0, σ2 < 0 → α = –∞ → β = –2

−2 ≤ β ≤ 1
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Balanced-biaxial stretching
Equibiaxial: tiramos de los dos lados lo mismo

There is a great reduction in

thickness:

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Plane strain

Thickness decreases:

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Uniaxial tension

Thickness decreases:

El espesor se reduce menos porque el area se conserva cada vez mas

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Pure shear

thickness
reduces

There is no thickness reduction:

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 Uniaxial compression

thickness
reduces

thickness
increases

Sheet thickness increases:

Se comprime más de lo que se expande por lo que el espesor aumenta

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CONSTITUTIVE MODELS

Determination of the true stress-strain curve from a tensile test:

Measurements:

Engineering stresses and strains:

True stresses and strains:

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Stress-strain constitutive models

a) Materials without previous deformation (e.g. annealed materials).

b) Materials with previous deformation (e.g. cold worked materials).

c) Materials without hardening.

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Bibliography
Marciniak, Z., Duncan, J. L. and Hu, S.J. (2002), Mechanics of Sheet Metal
Forming. Butterworth-Heinemann, Oxford. [Online: fama.us.es]

Chapter 2. Sheet deformation processes.

Chapter 3. Deformation of sheet in plane stress.

Hosford, W.F. and Caddell, R.M. (1993), Metal Forming. Mechanics and
Metallurgy, Prentice Hall. [Online: fama.us.es]
• Chapter 12. Bending.
• Chapter 14. Cupping, redrawing, and Ironing.
• Chapter 16. Stamping.
• Chapter 17. Other Sheet-Forming Operations.

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