Bending Force Requirement

Force Punch

WT 2 F = (UTS ) L
T

Workpiece

Die
L

T = Sheet Thickness W = Total Width Sheared

(into the page)

L =Span length UTS = Ultimate Tensile Strength of material e = 1/

Engineering Strain during Bending: ((2R/T) + 1) Minimum Bend radius:

5/26/12 R = Bend radius r = tensile area reduction in percent

R = T ((50/r) 1)

Pure Bending

tension

compression

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Bending & Stretching

Stretch Forming

Loading

Pre-stretching

Wrapping

Release

* source: http://www.cyrilbath.com/sheet_process.html

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Stretch forming

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Stretch Forming Force Requirement

F = (YS + UTS)/2 * A F = stretch forming force (lbs) YS = material yield strength (psi) UTS = ultimate tensile strength of the material (psi) A = Cross-sectional area of the workpiece (in2) Example of Force Calculation

Calculate the force required to stretch form a wing span having a cross-sectional area of .50X120 made from 2219 aluminum alloy having a yield strength of 36,000 psi and a UTS of 52,000 psi:

F = 88000/2 * 60 = 2,640,000 lbs = 1320 tons

Calculate the force required to shear a 10 diameter, 1/8 thick blank from mild steel with a UTS of 45,000 psi: 5/26/12 0.7 (.125)()(10) 45,000 = 62 tons F=

 Stretch Forming Advantages over Stamping

Design: Stretch Forming vs. Stamping

Tighter tolerances are possible: as tight as . 0005 inches on large aircraft parts Little problem with either wrinkling or spring back Large, gently contoured parts from thin sheets

Stretch forming Disadvantages over Stamping

Complex or sharply cornered shapes are difficult or impossible to form Material removal blanking, punching, or 5/26/12 trimming requires secondary operations

Stretch Forming Sheet metal is stretched and simultaneously bent to achieve shape change

(1) start of process (2) die is pressed into the work with force Fdie, causing it to be stretched and bent. F = stretching force The shape is produced entirely by tensile stretching so the limiting strain is that at necking. It can 5/26/12 be thought of as a uniaxial tensile stress condition. And the forming limit is reached when the local strain equals

Suranaree University of Technology Jan-Mar 2007 Stretch formiing Forming by using tensile forces to stretch the material over a tool or form block. used most extensively in the aircraft industry to produce parts of large radius of curvature. (normally for uniform cross section). required materials with Stretch forming feasible for appreciable ductility. aluminium, Springback is largely eliminated stainless steel, titanium. because the stress gradient is relatively uniform. www.ducommunaero.com Stretch forming feasible for aluminium, stainless steel, titanium. www.dynabil.com Tapany Udomphol Form block is slowly raised by the ram to deform sheet above its yield point. 5/26/12

Suranaree University of Technology Jan-Mar 2007 Bendiing The bend radius R = the radius of curvature on the concave, or inside surface of the bend. Fibres on the outer surface are strained more than fibres on the inner surface are contracted. Fibres at the mid thickness is stretched. Decrease in thickness (radius direction) at the bend to preserve the constancy of volume. R thickness on bending Tapany Udomphol

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Condition: - No change in thickness - The neutral axis will remain at the centre fibre. - Circumferential stretch on the top surface ea = shrink on the bottom surface, eb The minimum bend radius For a given bending operation, the smallest bend radius can be made without cracking on the outer tensile surface. Normally expressed in multiples of sheet thickness. Example: a 3T bend radius means the metal can be bend without cracking though a radius equal to three times the sheet thickness T. 5/26/12

Springback Dimensional change of the formed part after releasing the pressure of the forming tool due to the changes in strain produced by elastic recovery.

Springback is encountered in all forming operations, but most easily occurs in bending. 5/26/12

Tube bending Tube bending www.precision-tube-bending.com Bending of tube and structural material for industry, architecture, medical, refinery. Heat induction and hot slap bending require the heating of pipe, tube or structural shapes. Heat Induction bending is typically a higher cost bending process and is primarily used in large diameter material.

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In the stretch forming process, a metal sheet is formed by the application of tensile loads to the material to produce the required shape. The sheet is clamped in jaws at both ends and stretched into plastic condition over a forming tool as shown in Fig. 22a, b. Two versions of the process are used: stretch forming and stretch-wrap forming. In the stretch forming process, the tool moves into the clamped sheet as shown; in stretch-wrap forming, the sheet is first stretched beyond the plastic limit and then wrapped over the form block as shown. The process is used to produce body parts for aircrafts, trucks, cars, and rocket motor housings, where the geometry has rather gentle shape and is free of sharp bends. The advantages of stretch forming are: Only one die is needed. The die can be made of inexpensive material. Contours with compound contours are possible. Spring back is almost absent. 5/26/12

The stretching and resulting sliding at the interface between die and sheet causes friction, and consequently the tension in the sheet will vary from a maximum at the jaws and gradually decreasing inward against the sliding direction. As shown later in the discussion on bending, spring back is a problem for pure bending. If tensile stresses are superimposed, the neutral line will move toward the concave side of the bend. If those tensile stresses become so large that the neutral line disappears, i.e., the outer side as well as the inner side of the bend are deformed in tension, the spring-back problem is almost eliminated, which is an important advantage for stretch forming processes.

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COLD-WORKING PROCESSES Cold working is the plastic deformation of metals below the recrystallization temperature. In most cases of manufacturing, such cold forming is done at room temperature. In some cases, however, the working may be done at elevated temperatures that will provide increased ductility and reduced strength, but will be below the recrystallization temperature. When compared to hot working, cold-working processes have certain distinct advantages: 1. No heating required 2. Better surface finish obtained 3. Superior dimension control 4. Better reproducibility and interchangeability of parts 5. Improved strength properties 6. Directional properties can be imparted 7. Contamination problems minimized

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Some disadvantages associated with cold-working processes include: 1. Higher forces required for deformation 2. Heavier and more powerful equipment required 3. Less ductility available 4. Metal surfaces must be clean and scale-free 5. Strain hardening occurs (may require intermediate anneals) 6. Imparted directional properties may be detrimental 7. May produce undesirable residual stresses

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