Problem solving session 4

Problem 1 (Bending problem)

A bending operation is to be performed on 4.0 mm thick cold-rolled steel sheet that is 25 mm wide
and 100 mm long. The sheet is bent along the 25 mm direction, so that the bend is 25 mm long.
The resulting sheet metal part has an acute angle of = 30and a bend radius of R = 6 mm.
Determine:
(a) Bend allowance;
(b) The engineering strain at the inner surface of the bent sheet.

Solution:
(a) Given that = 6.0 , = 30, = 4.0
bend angle = 180 30 = 150,

bend allowance = ( + ) = (180) ( + )

6
= = 1.5, 2.0; , = 0.333
4
150
= (
) (6 + 0.333 4) = 19.195
180
(b) The length along the neutral axis wont change during bending. By definition, the
engineering strain can be computed as
0
=
0
0 =
( + )

=
=
=

( + )
+
+ 1

1
Given that = 0.333 and = 1.5, = 1.5
0.1817
0.333

+1

Problem 2 (Drawing)
A tension test on a sheet steel fabricated by a rolling operation showed a 30% elongation in length
and a 16% decrease in width. The test was conducted in rolling direction (0), and assume the
material exhibits the same tensile behavior in the other directions, i.e., 45 to the rolling direction
(45), and perpendicular to the rolling direction (90).
Estimate the limiting draw ratio that would be expected for the steel.
Solution:

Given that

0
0

= 1.30 and

= 0.30 and

0
0

= 0.16, we then have

= 1 0.16 = 0.84

The normal anisotropy in rolling direction (0) can then be computed as

0
1
(
)
0.84) 1.98
0 =
=

(0.84 1.30)
( )
0 0
(

Since the material exhibits the same tensile behavior in the other directions
45 = 90 = 0 = 1.98 = 1.98
According to Figure 7.56 on Slide 50, the limiting draw ratio around 2.7.

Problem 3 (Drawing problem)

A cup is to be drawn in a deep drawing operation. The height of the cup is 75 mm and its inside
diameter = 100 mm. The sheetmetal thickness = 2 mm. If the blank diameter = 225 mm.
Determine:
(a) Drawing ratio
(b) Reduction
(c) Thickness-to-diameter ratio
(d) Does the operation seem feasible?
(e) Does the operation seem feasible if the starting black size diameter = 175 mm?
Solution:
D

225

(a) DR = D = 100 = 2.25

p

(b) =
(c)

t
D

225100
225

= 0.555 = 55.5%

= 225 = 0.0089 = 0.89%

(d) Feasibility? No. DR is too large (greater than 2.0), r is too large (greater than 50%), and
t/D is too small (less than 1%).
D

175

(e) DR = D = 100 = 1.75. =

175100
175

= 0.429 = 42.9

2
=
= 0.0114 = 1.14%
175
Feasibility? DR < 2.0, r < 50%, and t/D > 1%. However, the operation is not feasible
because the 175 mm diameter blank size does not provide sufficient metal to draw a 75
mm cup height. The actual cup height possible with a 175 mm diameter blank can be
determined by comparing surface areas (one side only for convenience) between the cup
and the starting blank.
=

2
4

(175)2
4

= 24053 2

To compute the cup surface area, let us divide the cup into two sections: (1) walls, and
(2) base, assuming the corner radius on the punch has a negligible effect in our
calculations and there is no earing of the cup.
Thus, = +
7854

2
4

= 100 +

(100)2
4

= 100 + 2500 = 314.16 +

Set surface area if cup = surface area of starting blank:

314.16 + 7854 = 24053

= 51.56

This is less than the specified 75 mm height.

Problem 4 (Sheet metal forming)

After a series bulge tests, the original circular grids of 0.084 (0 ) inch in diameter have deformed
into the following dimensions:

Determine:
(a). Forming limit diagram.
(b). After a bulge test, a circular grid (A) have deformed into the following shape. Mark it on
the forming limit diagram. Would it fail?

Solution:

(a) The major strain ( ) and minor strain ( ) can be calculated by:
= (2 0 )/0 , = (1 0 )/0

Only an
approximation
Values plotted can be in
percent (this graph) or not.
(b) The major and minor engineering strains can be computed as follows:
= (2 0 )/0 = (0.136 0.084)/0.084 = 0.62
= (1 0 )/0 = (0.08 0.084)/0.084 = 0.048
Based on the approximated limit curve, the grid (A) is likely to fail.

Problem 5 (Concept)
1. Match the letters corresponding to the different Sheet metal forming methods in the figure to
their names.

Answer:
Bulge test
Edge bending
Drawing
V-bending

__D__
__A__
__C__
__B__

2. The recovery observed after deforming a sheet material is due to the plastic strain energy stored
during deformation
True
False