Sheet Metal Forming I

Simulation Techniques in Manufacturing Technology

Lecture 3
Laboratory for Machine Tools and Production Engineering
Chair of Manufacturing Technology

Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. F. Klocke

WZL/Fraunhofer IPT

Outline
1

Introduction

Sheet Material

Sheet Metal Forming Techniques

3.1 Deep Drawing Process
3.2 Ironing Process
3.3 Bending Process
3.4 Stretch Forming Process
3.5 Spinning Process
3.6 Hydroforming

WZL/Fraunhofer IPT

Seite 1

Introduction

Methods of Forming Classification DIN 8580 ff

Manufacturing processes

Casting

Compressive
forming

Open die forging

Closed die forging
Cold extrusion
Rod extrusion
Rolling
Upsetting
Hobbing
Thread rolling

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Forming

Tension
compressive
forming

Deep drawing
Ironing
Spinning
Hydroforming
Wire drawing
Pipe drawing
Collar forming

Cutting

Tensil forming

Stretch forming
Extending
Expending
Embossing

Joining

Bending

With linear

tool
movement

With
rotatory tool
movement

Coating

Shear forming

Translate

Twist

Intersperse

Changing of
material properties

severing

Shearing

Fine Blanking

Cutting with a

single blade

Cutting with two
approaching blades

Splitting

Tearing

Seite 2

Techniques of Metal Forming: Bulk Forming Sheet Metal Forming

Bulk forming:

Sheet metal forming:

High changes in diameter and

No or low unwanted changes of the

dimensions

original wall thickness

High deformation

Lower deformation

High material hardening

Lower material hardening

High forces

Lower forces

High tool stresses

than in bulk forming

WZL/Fraunhofer IPT

Seite 3

Outline
1

Introduction

Sheet Material

Sheet Metal Forming Techniques

3.1 Deep Drawing Process
3.2 Ironing Process
3.3 Bending Process
3.4 Stretch Forming Process
3.5 Spinning Process
3.6 Hydroforming

WZL/Fraunhofer IPT

Seite 4

Sheet Material

Difference Between Sheet Material and Bulk Material

sheet
coil (width, length thickness)
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bulk
slab (460 x 1400 x 3400)
Seite 5

Sheet Material

Manufacturing of Sheet by Flat Longitudinal Rolling

Coil velocity is considerably higher than

slab velocity
(v1 400 v0)

Roller

l1 >> l0
Strip

The lenghtwise extension of the sheet leads to

directionally dependent material properties.

WZL/Fraunhofer IPT

Seite 6

Sheet Material

Definition of Anisotropy Values

Rolling
direction
Direction of pattern:

Strip

Impact of anisotropy
Perpendicular anisotropy r

Examination of anisotropy

Angle to rolling direction /

The term anisotropy describes:

The material properties dependance on the orientation to the rolling direction.

In sheet metal processing:
 perpendicular anisotropy r (depending on sheet thickness) and
 plane anisotropy r (depending on sheet plane) are encountered.

Anisotropy has to be considered in the dimensioning of forming processes
WZL/Fraunhofer IPT

Seite 7

Sheet Material

Forming Property: Measuring Grid Technique

b = ln

b1
d0

l = ln

l1
d0

Deformation of the measuring grid because of tensile and compression stresses inside

the sheet metal while forming

The effective strain can be derived from the grid deformation = maximum deformation

(forming limit)
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Seite 8

Sheet Material

Forming Property: Forming Limit Curve

Definition: 1 > 2
Test conditions:
deep drawing test with hemispherical
stamp and straight strip

Strain 1

Failure
Tensocompressive

Well

Quelle: ThyssenKrupp

Tenso-tenso

Variable strip thickness to vary 2 (one test

corresponds with one value of 2)
Material: RR St 1403
Sheet thickness : 1 mm

Strain 2

Determination of forming limit curve

to predict failure by using FEM

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Seite 9

Sheet Material

Delivery Possibilities for Sheet

Hot rolled strip
 thin sheet
 thick plate

Cold rolled strip
 thin sheet
 thick plate

Surface finished sheet

Tailored blanks

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Seite 10

Sheet Material

Development of High Strength Sheet Materials

Elongation at Fracture A80 / %

Soft

High
strength

Higher strength

Highest strength

80

60

IF

40

20

200

400

600

800

1000

1200

1400

Tensile Strength Rm / MPa

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Seite 11

Material Sheet

Production of Tailored Blanks

Quelle: ThyssenKrupp

Door of
passenger car

Floor of
passenger car

Coil material can be made of sheets differing in

thickness and strength. Ulterior motive is the

production of sheet components with differing
sheet thickness considering feasible loadings .
WZL/Fraunhofer IPT

Seite 12

Outline
1

Introduction

Sheet Material

Sheet Metal Forming Techniques

3.1 Deep Drawing Process
3.2 Ironing Process
3.3 Bending Process
3.4 Stretch Forming Process
3.5 Spinning Process
3.6 Hydroforming

WZL/Fraunhofer IPT

Seite 13

Outline
1

Introduction

Sheet Material

Sheet Metal Forming Techniques

3.1 Deep Drawing Process
3.2 Ironing Process
3.3 Bending Process
3.4 Stretch Forming Process
3.5 Spinning Process
3.6 Hydroforming

WZL/Fraunhofer IPT

Seite 14

Sheet Metal Forming

Deep Drawing

Stretch forming

Spinning

Deep drawing

Ironing
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Bending

Hydroforming
Seite 15

Deep Drawing Process

Deep Drawing of a Plane Round Sheet Plate

Punch

Blank holder

Sheet
metal

Drawing die

WZL/Fraunhofer IPT

Seite 16

Deep Drawing Process

Material Flow from Flange to Cup Wall

a = Material to be bend
b = Material to be displaced
Before forming

After forming

Material displacement in circumferential

direction causes tangential compressive

stresses in the flange region.
WZL/Fraunhofer IPT

Seite 17

Deep Drawing Process

Problem: Formation of Wrinkles in the Flange

By exceeding buckling instability

of the sheet material, the tangential

compressive stresses produce
wrinkles in the flange
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Seite 18

Deep Drawing Process

Failures in Deep Drawing

Earing
 Plane anisotropy

Eccentric position
of circular blank
 Mistake of user

Cup base fracture

Exceeding of tensile
strength of the material

Lip formation
Increased strain
hardening of the
material in edge
region
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Seite 19

Deep Drawing Process

Redrawing (Multi-Station Die)

Punch
Blank holder
Predrawed
cup
Back-up ring

Drawing die

Production of

rotationally symmetrical
components by
redrawing to reduce
loadings on tools and
workpiece
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Seite 20

Deep Drawing Process

Use of Brake and Drawing Beads

Deep drawn engine bonnet

Blank holder

Die

Punch

Draw bead

Use of brake or drawing beads to manage the material

flow during drawing

WZL/Fraunhofer IPT

Seite 21

Deep Drawing Process

Deep Drawn Mudguard

Avoidance of buckling during the forming of asymmetrical components by the use of

symmetrical geometry arrangement

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Seite 22

Deep Drawing Process

Deep Drawing of Car Body Components

Quelle: Daimler
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Seite 23

Deep Drawing Process

Deep Drawing with Elastic Tools and Liquid Media

Punch
Deep drawing
with rubber
stamp

Rubber
Workpiece

Deep
drawing with
rubber pad

Membrane
Water

Liquid

Workpiece
Deep
drawing
with water
bag

Rubber core

Deep drawing
with
membrane

The application of a rubber pad or a membrane, which is filled with a liquid medium, is universal
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Seite 24

Deep Drawing Process

Deep Drawing with Elastic Tools and Liquid Media

Deep drawing
with fluid
pressure on
one side

Workpiece

Deep drawing
with fluid
pressure on both
sides

Membrane
Vacuum

Deep drawing
with
positive pressure
on one side

Vacuum

Deep drawing
with
negative pressure

Workpiece

The process limits of deep drawing with rigid dies can be enlarged or

circumvented
WZL/Fraunhofer IPT

Seite 25

Outline
1

Introduction

Sheet Material

Sheet Metal Forming Techniques

3.1 Deep Drawing Process
3.2 Ironing Process
3.3 Bending Process
3.4 Stretch Forming Process
3.5 Spinning Process
3.6 Hydroforming

WZL/Fraunhofer IPT

Seite 26

Sheet Metal Forming

Ironing

Strech forming

Spinning

Ironing

Deep drawing
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Bending

Hydroforming
Seite 27

Ironing Process

Schematical Description of Ironing

Punch
Sheet forming = Production of plane hollow
bodies without required change of wall
thickness

Ironing = Bulk forming

Workpiece
Ironing die

Ironing is applied for a defined reduction of the wall

thickness of a deep drawn workpiece

WZL/Fraunhofer IPT

Seite 28

Ironing Process

Multi-stage Ironing Influence of workpiece velocity

Achievement of high wall

thickness proportions by multistation ironing

Because of the difference in

Punch

velocity between intake and

runout, the workpiece should
have left the first ironing die
before running into the next

Distance

Workpiece

Ironing dies

S
t

WZL/Fraunhofer IPT

Seite 29

Ironing Process

Progression of Force for Different Distances of Ironing Dies

Drawing Force

1,2,3: Single drawings

4: Triple drawing

Ironing die

d2 az
Zwischenring
Distance ring
Abstreckring
Ironing die

Increase of resulting force in triple

drawing,
Risk of cup base fracture.

Punch Displacement

Ironing die

d2

Ironing die

2
az

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az

Large distance between ironing dies:

d1

1,2,3: Single drawings

4: Triple drawing
Distance ring

Low distance between ironing dies:

az az

Drawing Force

d1

az

Decrease of resulting force in

triple drawing,
Large stroke of punch required.

Punch Displacement

Seite 30

Ironing Process

Production of a Beverage Can

High strains can be reached by the use of

several ironing steps

Source: Visypack, Ball Europe

WZL/Fraunhofer IPT

Seite 31

Outline
1

Introduction

Sheet Material

Sheet Metal Forming Techniques

3.1 Deep Drawing Process
3.2 Ironing Process
3.3 Bending Process
3.4 Stretch Forming Process
3.5 Spinning Process
3.6 Hydroforming

WZL/Fraunhofer IPT

Seite 32

Sheet Metal Forming

Bending Process

Stretch forming

Spinning

Bending

Deep drawing
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Ironing

Hydroforming
Seite 33

Bending Process

Classification of Bending Techniques

Forming by bending
Forming by bending with linear tool movement
Drawing by a
sliding action

Open bending

Die bending

Straightening

Radial die
forming

Open circular b.

Die flanging

B. without radial
stress

Radial die forming

Edge rolling

Bending by
bulging

Winding

Crimping
Roll straightening
Corrugating
Roll forming to shape

Coiling

Rotary bending

Circular bending

Roll draw bending

Swing-folding

Roll bending

Forming by bending with rotatory tool movement

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Seite 34

Bending Process

Distribution of Stresses and Straines during Bending

y
bl

el

pl

pl

el - Elastic elongation
s0 /
2
Neutral fiber

Yielding point
x; x

pl - Plastic elongation
bl - Permanent elongation
after springback

s0 /
2

State of stress under load

State of stress after springback

Ideal plastic material
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Seite 35

Bending Process

The Springback Issue

Residual stresses of

component lead to
springback

The state of residual

stresses after forming

depends on the reaction of
the material deformation

The flow behaviour at load

inversion depends on
history of deformation
(Bauschinger-Effect)

Stainless steel
Aluminium
Copper
High strength
steel
Steel

Quelle: IWM

WZL/Fraunhofer IPT

Seite 36

Bending Process

Deformation in Bending Zone

Workpiece

Reduction of cross section and

deformation along the bending edge

occurs when having thick sheets and
small bending radii

Clamping jaw

S : Sheet thickness
Ri: Inner radius
Ra: Outer radius
Fiber of no extension

Workpiece

Especially in case of open bending

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Middle fiber
(Neutral fiber)

Region of cross section reduction by

stretching
Seite 37

Bending Process

Roll Forming to Shape

Workpiece

Initial state

Distance
between
roller-pair

Upper roll

Final state
Lower roll
1. Step

4. Step

6. Step

5. Step

7. Step

2. Step

3. Step

Strips of optional length

can be formed
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Seite 38

Bending Process

Examples of Operation Steps using Die Bending

1. and 2.
Step

1. Step
WZL/Fraunhofer IPT

3. and 4.
Step

2. Step

5. and 6.
Step

3. Step

7. Step

4. Step
Seite 39

Bending Process

Arrangement of Rollers at Three-Roll Bending Machines

Symmetrical
three-roller bending machine

Roll bending is mainly used for rolling of thin, medium and

thick plates for producing tubes and tubular workpieces.

By variation of roll position non-rotationally symmetric
workpieces can be produced as well.
Quelle: Bergrohr

WZL/Fraunhofer IPT

Seite 40

Outline
1

Introduction

Sheet Material

Sheet Metal Forming Techniques

3.1 Deep Drawing Process
3.2 Ironing Process
3.3 Bending Process
3.4 Stretch Forming Process
3.5 Spinning Process
3.6 Hydroforming

WZL/Fraunhofer IPT

Seite 41

Sheet Metal Forming

Stretch Forming

Stretch forming

Bending

Deep drawing
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Ironing

Spinning

Hydroforming
Seite 42

Stretch Forming Process

Difference Between Bending and Stretch Forming: The Neutral Fiber

Stretched zone
Neutral fiber

Stretch formed profile

Upset
zone

Stretched zone

Sheet thickness

Open bended profile

Reduction of springback by stretch

forming
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Neutral Fiber (outside of the sheet)

Seite 43

Stretch Forming Process

Sketch of a Stretch Forming Press

Workpiece

Forming punch
Collet chuck

Bottom plate

Piston

Hydraulic cylinder

Low tool and machine costs concerning the size of the work pieces being produced
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Seite 44

Stretch Forming Process

Stretch Forming Failures

Constriction with following
crack

Brittle fracture

Cracks near to collet chucks

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Cracks in vertex region

Seite 45

Stretch Forming Process

Stretch Forming Techniques

Workpiece
Waste
material

Lost end

Basic stretch forming (high amount of

waste material)

Waste
material

Workpiece

Tangential stretch forming (low amount of waste

material)

Tangential stretch forming (underdrawing possible, higher process flexibility)

WZL/Fraunhofer IPT

Seite 46

Stretch Forming (+ Deep Drawing)

Drawing of Car Body Panels

Drawing of car body panels

Stretch forming

Deep drawing
Drawing of car body panels
Punch

Blank holder
With break
bead

Source: PtU

Die

Real drawing of a car body panel is always a combination between stretch forming and

deep drawing
WZL/Fraunhofer IPT

Seite 47

Outline
1

Introduction

Sheet Material

Sheet Metal Forming Techniques

3.1 Deep Drawing Process
3.2 Ironing Process
3.3 Bending Process
3.4 Stretch Forming Process
3.5 Spinning Process
3.6 Hydroforming

WZL/Fraunhofer IPT

Seite 48

Sheet Metal Forming

Spinning

Bending

Stretch forming

Spinning

Deep drawing
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Ironing

Hydroforming
Seite 49

Spinning Process

Spinning Process (Sketch) with Intermediate Stages

s0 : Sheet thickness of circular blank
do : Diameter of circular blank
0 : Basic shape
1-6 : Intermediate stages
7 : Final stage

Projizierstreckdrcken

Spinning roll

Spinning chuck
Counterholder

animated
animiert

Workpiece

Low tool costs and cycle times in comparison to alternative processes

WZL/Fraunhofer IPT

Seite 50

Spinning Process

Spinning Techniques
Gegenwerkzeug
Counter tool

Spinning roll
Drckwalze

Drckform
Spinning
form

Counterholder
Gegenhalter

Counterholder
Gegenhalter

Drckstab
Spinning bar

Engen durch
Drcken
Contracting
by spinning

Spinning of
external
flanges
Erzeugen
von
Auenborden
durch Drcken
WZL/Fraunhofer IPT

Aufweiten durch
Drcken
Expanding
by spinning

Erzeugen
von Innenborden
Spinning
of
durch
insideDrcken
beads

Drckwalze
Spinning
roll

Einhalsen
durch
Drcken
Necking by
spinning

Workpiece
Werkstck

Gewindedrcken
Thread spinning
Seite 51

Spinning Process

Ironing by Spinning in Same and Opposite Direction

Spinning
chuck
Drckfutter

Counterholder
Gegenhalter

Same direction process

Flow of material in direction of tool
movement

Drckrolle
Spinning
roll

Spinning chuck
Drckfutter

Opposite direction process

Flow of material in opposite
direction of tool movement

Drckrolle
Spinning roll
WZL/Fraunhofer IPT

Seite 52

Spinning Process

Defects in Production when Spinning a Cup

Radial cracks by tangential

compression and bending stresses

Formation of wrinkles by tangential

compression and bending stresses

Tangential cracks by
radial or axial tensile stresses

During spinning axial and radial tensile stresses occur as well

as tensile and compressive stresses in tangential direction.

These stresses can finally lead to an overload of the
workpiece.
WZL/Fraunhofer IPT

Radial cracks by
tangential tensile stresses
Seite 53

Spinning Process

Maximum Accepted Spinning Proportion

Spinning Proportion max

Material St 13
dW/d1 = 1,5

Related sheet thickness s0/d1

WZL/Fraunhofer IPT

Seite 54

Spinning Process

Force Components at Spinning Process

Ft

F
a

Fr

Fr

Fa = Axial force
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Fr = Radial force

Ft = Tangential force
Seite 55

Spinning Process

= 1.2
= 0.1
= 0.2
= 0,17 10-2

Material St 13
Diameter after
conditioning d1
Diameter of spinning roll dW

Specific Axial Force Fa / d12 / MPa

dW / d1
W / d1
W / d1
f / d1

Specific Radial Force Fr / d12 / MPa

Axial und Radial Force at Spinning Process

Axial Force

Curvature of roll W
Feed f

Spinning Proportion = d0 / d1

Radial Force

Spinning Proportion = d0 / d1

Forming forces increase when feed and initial sheet thickness are increased.

Axial and radial forces are influenced by spinning proportion and curvature radius W of spinning

roll without reduction of sheet thickness.

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Seite 56

Spinning Process

Spinning Process by Manual Work

Source: MetalSpinners

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Seite 57

Spinning Process

Roll Spinning Pulley

Source: Leico

WZL/Fraunhofer IPT

Seite 58

Spinning Process

Components

Aluminium reflectors

Rocket tank bottom

Aluminium-car-rim
Source: Leifeld

WZL/Fraunhofer IPT

Seite 59

Spinning Process

Laser Aided Spinning

Machine Set-Up

Process

Increase of forming limit because of local heat input

WZL/Fraunhofer IPT

Seite 60

Outline
1

Introduction

Sheet Material

Sheet Metal Forming Techniques

3.1 Deep Drawing Process
3.2 Ironing Process
3.3 Bending Process
3.4 Stretch Forming Process
3.5 Spinning Process
3.6 Hydroforming

WZL/Fraunhofer IPT

Seite 61

Sheet Metal Forming

Hydroforming

Strech forming

Spinning

Hydroforming

Deep drawing
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Ironing

Bending
Seite 62

Hydroforming

Principles of Hydroforming
ProzessInitiation
of
beginn
process

ProzessEnd of
ende
process

keine
externe
No external
Druckversorgung
pressure supply

Expanding in a closed tool

WZL/Fraunhofer IPT

Seite 63

Hydroforming

Production of a T-Part
Counterholder

Close press

Tube
Halves of formtool

Fill up with
fluid medium

Move horizontal
cylinder, adjust
water pressure,
direct counterholder

Open press,
eject part

WZL/Fraunhofer IPT

Seal stamp

Secondary form

T-part

Seite 64

Hydroforming

Production of a Engine Bracket

Hydroforming tool

Engine bracket with add-on parts

In comparison to conventional construction:

30 % lower weight,

20 % lower costs,

60 % lower tool costs.
WZL/Fraunhofer IPT

Seite 65

Hydroforming

Production of a Engine Bracket

Axial cylinders seal ends

of tubes

Preformed piece is flooded

by hydromedium

Forming with internal

pressure of 1.500 bar

Final shape of workpiece

depends on die cavity

Axial cylinders add

material by sliding

Punching after forming;

slugs are bend down

inside

WZL/Fraunhofer IPT

Seite 66

Hydroforming

Examples of Components in the Field of Car Body

Audi TT
Roof frame
lateral l./r.

Reinforcement
Eaves gutter l./r.

Transversal
bar of windscreen

Closure pipe

Main pipe

Control arm

Rear bottom
transversal bar
Sillboard l./r.
Transversal bar of seat l./r.

Audi A6

Production of high strength life and weight optimized components and units
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Seite 67