Taiyuan University of Technology

Sheet Metal Forming Processes and Die Design

College of Materials Science and Engineering LecturerCAO Xiao-qing March,2009

Chapter 6 Bulging and Flanging Main contents:

Flanging of a hole (dimpling) Flanging of outer edge; Bulging(expanding) and local forming

Key points:
Deformation feature of bulging and hole flanging

New Words: Flanging/dimpling, bulging, Ironing Flanging()nosing() concave stretch flange() convex shrink flange() Spinning() local forming() Flexible die forming()

6.1 Flanging
Definition and classification Flanging of a hole Flanging of outer edge Ironing flanging

1.Definition and classification

definition: plane sheet(semi-product) vertical edge along certain straight line or curve via flanging die classification: flanging of a hole and flanging of outer edge

2.Flanging of a hole
A hole is drilled or punched and the surrounding metal is expanded into a flange.

2.1 Deformation feature

deformation zone: a ring of D-d

(+ ) > (), (+ ), (+ )
risky section : edge fracture(type: local extension is not enough)

2.2 Deformation degree

flanging coefficient: m=d/D limit flanging coefficient[m]: maximum deformation degree of no fracture

2.Flanging of a hole

Phases in the procwss of flanging of a hole

2.Flanging of a hole
factors affecting [m]:
materials property;: [m] relative thickness: d0 / t[m] state of edge: smooth[m]<rough[m] shape of flanging punch: flat[m]>spherical[m] shape of hole: circular[m]>un-circular[m]

2.Flanging of a hole
2.3 Calculation of blank
principle: neutral line length is constant. punching hole in plane sheet: calculate the diameter of pre-punched hole from the size of workpiece ,then check it with [m]

calculate Hmax using [m],then compare with Hworkpiece punching hole in the bottom of drawing work-piece

2.4 Flanging force

estimate using empirical formula

2.Flanging of a hole
2.5 Determination of flanging die

2.Flanging of a hole

3.Convex-shrink flange
Shrinkage : wrinkle , (), = b /( R + b) Tension : edge fracture, (+), = b /( R b) Blank calculating principle: constant neutral line length

4.Ironing flanging
Blank calculating principle : constant volume Difference between general flanging and ironing flanging

6.2 Bulging and local forming

Bulging Local forming

1.Bulging
1.1 Deformation feature deformation region: stable (<d), double axial tension stress, thickness of the material thinner, unstable form is fracture(type: strength is not enough) 1.2 Deformation degree expressing index affecting factors

1.Bulging
1.3 Bulging dies

Vertical or horizontal segmented dies are commonly used for bulging, the force being applied by either hydraulic or mechanical means.

Mechanical bulging die

1.Bulging
Require sealing and control of the hydraulic pressure.

Bulging die with an elastic insert

2.Local forming
2.1 Nosing
A die reduction method whereby the top of a cup or a tubular shape may be closer or smaller in diameter than its body. Nosing compresses the work metal, resulting in an increase in length and wall thickness. There are three types of end profiles after nosing: Frustum of cone Neck Segment of sphere.

2.Local forming
2.2 Spinning
The process of forming a metal part from a circular blank of sheet metal or from a length of tubing over a mandrel with tools or rollers. There are three types of spinning processes: Type I: manual spinning. Type II:shear spinning. Type III: tube spinning. consists of reducing the thickness of a cylindrical work piece while it is spinning on a cylindrical form block.

2.Local forming
A circular blank of sheet metal is held against a form block and rotated while a rigid tool is used to deform and shape the workpiece over the form block. The tools may be operated manually or by a hydraulic mechanism. Pros: speed, economy less tooling costs small investment in equipment Cons: requires more skilled labor

Manuals pinning process

2.Local forming
The shape is generated by keeping the diameter of the workpiece constant. Forming complex shapes, such as cones with tapering walls; symmetrical-axis curvilinear shapes, such as nose cones; and hemispherical and elliptical tank closures with either uniform or tapering walls.

Shear pinning method

2.Local forming
Consists of reducing the thickness of a cylindrical work piece while it is spinning on a cylindrical form block.
Tube pinning method

2.Local forming
2.3 Flexible die forming
In flexible die forming, one of the dies in a set (punch or die) is replaced with a flexible material such as a rubber or polyurethane membrane. Polyurethane is widely used because of its resistance to abrasion and long fatigue life. Note that the solid female or male die has been eliminated, thus reducing the cost of the operation. Furthermore, the surface of the workpiece is protected from damage or scorching during the forming operation. There are four basic types of flexible forming: Marform, Verson-Wheelon, Guerin, hydroform processes.

2.Local forming

Guerin

2.Local forming

Marform

2.Local forming

Hydroform