Design & manufacturing the bending die to study the phenomena in metal alloys

PART NAME Punch 1 Die Punch 2 WORCK SHOP Turning Turning Turning DIAMENSION 45 X 40 50 X40 41 X 40 WORCH SHOP Grinding MILLING Grinding DIAMENSION 45 X 40 120 X 50 X 50 41 X 40

Introduction
One of the most common material working operations is bending. This process is used not only to form parts such as flanges, seams etc. but to impart stiffness to the part by increasing its moment of inertia.The terminology used in bending. Spring back can be defined as elastically-driven change of shape of a deformed product which takes place during removal of external loads. It is a complex physical phenomenon there are several types of spring back in sheet metal.The outer fiber of the material are in tension and the Inner fiber of the material are in compression.

Preparation & manufacturing

Preparation of sheets

Results
Differences between 2mm and 4 mm sheets metal alloy thicknesses and springback is shown in (fig.)

Manufacturing flow diagram

Casting Rolling Trimming

The preparation of the sheet metal alloys done by three stages to reach the final dimension of the sheets 2 , 4 mm thickness

Manufacturing the die and the punches

The unconstrained cylindrical bending die and its punches is from carbon tool steel U10.manufacturing by milling and lathe machine. The first punch with R20.5 used to bend the sheet of 4 mm and the second punch R22.5 used to bend the sheet of 2 mm and the die radius 25 mm

Aim
The main object of the project is to design and manufacturing bending die and determine the spring back phenomena of lead , aluminum and copper alloys. By keeping all the variable constant except the thickness. The die is unconstrained cylindrical bending . The thickness of alloys specimens are 2mm and 4mm.

Experiment
punching
Aluminum Copper lead
Table 1 : Chemical compositions of copper sheets.
Zn% 0.01 Ag% 0.005 Pb% 0.02 Co% 0.01 Sn% 0.01 Cu% 99. 5 P% 0.007 Mn% 0.002 Fe% 0.005 Ni% 0.02 Si% 0.006 Al% 0.014 S% 0.003

springback
Fig. springback in sheets
Mn% 0.0005

Table 2 :The Chemical Composition of 7020 Alloy

Elements Si Fe Cu Mn Mg Cr Zn Ti Al Standard value < = 0.35 < = 0.40 < = 0.20 0.05 - 0.5 1 -1.5 0.10 0.35 45 0.08 BALANCE Measured value 0.121 0.290 0.200 0.0764 1.25 0.228 4.56 0.0319 BALANCE

Measuring
The spring back factor (K)

Table 3: Chemical Composition of the lead

Sb% 0.002 Ni% 0.001 As% 0.0005 Se% 0.0005 Bi% 0.005 Ag% 0.002 Cd% 0.0005 Te% 0.0005 Cu% 0.003 Sn% 0.001 Fe% 0.001 Zn% 0.002

conclusion
i.

As shown in (fig.) the springback K in lead sheets increase with the increase of its thickness. While in copper and aluminum sheets the springback factor K decrease with the decrease of its thickness. The aluminum sheets have the highest springback and the lead sheet of 2 mm thickness indicate no springback

When the hardness of the sheet increase the springback back factor (K) increase the sheets hardness Al. , Cu and Pb ( 72 ,57 , 36HRC ) respectively ii. The springback factor K=1 in lead alloy of 2 mm thickness that indicate there is no spring back in the sheet iii. Changing in the thickness of the sheet have big effect on the spring back iv. Aluminum sheets (AA7020 T6) have the biggest springback factor K v. In Al and Cu when the thickness increase the spring back factor increase while in Pb alloy when the thickness increase the springback factor decrease

Edited by the student

1.Manar Emad Mohammed 2.Mohammed Ali Fadhil 3.Mustafa Nabel Talib 4.Rand Murtadha Awad

supervisor

Asst. Prof. Dr. Hani Aziz Ameen

In Bending ,after plastic deformation there is an elastic recovery this recovery is called spring back. Spring back can be calculated approximately in terms if radii Ri and Rf Ri/Rf = 4 ( Ri Y / ET )3 3 (Ri Y /ET) + 1 Spring back Increases as (R/T ratio & yield stress of material ) increases as elastic modulus E decreases

References
1. J.R. Cho, S.J. Moon and S.S. Kang, Finite Element investigation on Springback, 2003, 141(1), 109-116. 2. Wagoner, R. H. and Li, M. Simulation of springback, 2007, 23, 345-360 3. Gan,W. and Wagoner, R.H. Die design method for sheet springback. Int. J. Mech. Sci., 2004, 46, 10971113. 4. Schmoeckel, D. and Beth, M. Springback reduction in draw-bending process of sheet metals 1993, 42(1), 339-342.