Die Design

Part 3- Forming Operation

Sources:

Handbook of Die Design, Suchy The Ohio State University Manufacturing Processes, Groover

Tool Design, 3331 Dr Simin Nasseri Southern Polytechnic State University

Forming

Similar to bending, but the blank is bent along a curved axis. There is little stretching or compressing of the material. All forming operations deform sheet material by exposing it to tension, compression, or both. Most part defects, such as splits and wrinkles, occur in forming operations. Successful sheet metal forming relies heavily on the metal's mechanical properties (the metal being formed must have the ability to stretch and compress within given limits). Some design considerations: Select the class of die, Choose number of stampings required, Cheapest and simplest tools may not be the best ones.

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Forming

Most common forming operations: Bending (will be reviewed in detail) Coining Embossing Flanging

Hole flanging or extrusion

Beading and curling Ironing Drawing

Forming die

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Coining

Coining dies create the part's shape by squeezing the metal under extreme pressure (up to yield strength of material). A simple round metal slug is placed into the die and forced to flow into a given shape by compressing it. Coining also can reduce the metal thickness.

Advantages: Capable of producing sharp, accurate bends with less sensitivity to material conditions. Disadvantages: High force requirements (tonnage is 5 to 10 times that required for simple air bending) Accelerated die wear (high forces increase machine deflection).
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Coins are created with the coining process.

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Embossing

Embossing dies use tension to stretch metal into a shallow depression. The dies primarily are comprised of a punch and a cavity. Most common applications: The stiffening of the bottom of a pan or container (in the form of ribs or crosses stamped in the metal) A small embossment often is used as a spotweld projection nib (metal is electrically welded together under controlled pressure and current). The metal's thickness and mechanical properties, along with the forming punch geometry, determine the depth that can be achieved.

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Flanging

Flanging is bending metal along a curved axis. Two basic types of flanges are stretch flanges (or tension flanges), and compression flanges (or shrink flanges). Tension flanges are susceptible to splitting, and Shrink flanges are susceptible to wrinkling. Flanges are created using a flanging die that wipes the metal between a punch and a lower die section.

Check the original edge of each part to understand the difference between compression and tension flanges.
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Hole Flanging or Extrusion

In extruding, the metal is flanged around the perimeter of a prepierced hole. Like during stretch flanging, the metal is susceptible to splitting during forming (this is sort of stretching operation). Extrusions also are referred to as hole expansions or continuous stretch flanges. Often extrusions are tapped for holding fasteners used in the part assembly process.

Flanges are made as countersunk, burred or dimpled holes.

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Hole Flanging or Extrusion (Countersunk)

For countersunk holes, it is necessary to coin the metal around the upper face and beveled sides to set the material. The holes are made about 0.005 in (0.13 mm) deeper than the required height of the rivet or screw head (allows the metal compression that occurs when squeezing the rivet in place).

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Beading & Curling

The edges of the ductile metal are formed into a roll or curl.
This is done to strengthen the part or to produce a betterlooking product. Curls are used in the manufacturing of hinges, pots, pans, and other items (sometimes wires may be rolled inside for strength). Radius of the curl twice the metal thickness.

Curling punch

Spring pad Spring pad 9

Metal to be curled MET3331, Prof Simin Nasseri, Dies, Part 3

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Ironing

Ironing dies are similar to coining dies in that they deform the metal with compression. However, unlike conventional coining, ironing squeezes metal along a vertical wall. This highly compressive process unifies a wall's thickness and increases the drawn vessel's length. Items such as beverage and soup cans are made using an ironing process. Ironing allows an aluminum can's wall thickness to be reduced to as little as 0.002 in.

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Drawing

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Drawing

Sheet metal forming to make cup-shaped, box-shaped, or other complex-curved, hollow-shaped parts. Sheet metal blank is positioned over die cavity and then punch pushes metal into opening. Products: Oil pans, automobile doors and fenders, cookware, and door knobs, beverage cans, ammunition shells, automobile body panels. Also known as deep drawing (to distinguish it from wire and bar drawing).

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Shapes other than Cylindrical Cups

Square or rectangular boxes (as in sinks), Stepped cups Cones Cups with spherical rather than flat bases Irregular curved forms (as in automobile body panels) Each of these shapes presents its own unique technical problems in drawing

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Drawing

Draw dies utilize a special pressureloaded plate or ring called a draw pad or blankholder to control the metal's flow into the cavity. This plate prevents the metal from wrinkling as it flows into the cavity. Increasing or decreasing the pressure exerted under the pad also controls how much metal feeds into the die.

(a) Drawing of cup-shaped part: (1) before punch contacts work, (2) near end of stroke; (b) workpart: (1) starting blank, (2) drawn part.
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Drawing

Although compression can occur when the metal is drawn, drawing uses mostly tension to obtain the part geometry.

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Clearance in Drawing
Sides of punch and die separated by a clearance c given by: c = 1.1 t where t = stock thickness

In other words, clearance c is about 10% greater than stock thickness

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Tests of Drawing Feasibility

Drawing ratio Reduction Thickness-to-diameter ratio

Successful deep draw progression

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Drawing Ratio DR
Most easily defined for cylindrical shape:

Db DR Dp

Db = blank diameter; Dp = punch diameter DR Indicates severity of a given drawing operation Upper limit: DR 2.0
Db Dp

Top view

Usually Db =< 2Dp

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t/Db and Reduction r

Thickness-to-Diameter Ratio = Thickness of starting blank divided by blank diameter Desirable for t/Db ratio to be greater than 1% As t/Db decreases, tendency for wrinkling increases

Reduction r = Defined for cylindrical shape:

Db Dp Db

Value of r should be less than 0.50

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Cool Design!

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Test yourself!

Name different components of this die. Draw the drawn part and explain how different components move with respect to each other.

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Test yourself!

Draw the drawn part (the final shape of the part) and explain how different components move with respect to each other..

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Forming Die- Design example

Design a die to form rectangular shapes along a strip which is continuously fed through the die.

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Forming (Retractable Die-holder Function )

Upward forming tool dies are retracted out of the way of the worksheet movements when forming is not in operation to avoid interference of forming die with the workpiece or Workholders.

This function allows obstacle free fast movement and improves the quality of the worksheet
http://www.mt-muratec.com/eg/p/product/tp/m2048lt.html

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