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THESIS
By
Ji You Yoon
2012
Jerald Brevick
Copyright by
Ji You Yoon
2012
Abstract
The dome test is a material test to evaluate formability and determine the flow
stress curve of the sheet materials. The dome test is a biaxial test which
consequently achieves greater maximum true strain without localized necking
compared to that of uniaxial tensile test. As a result, the flow stress curve obtained
from the dome test can be determined up to larger strains than in tensile test. This
reduces possible errors from extrapolation of flow stress curve obtained from
tensile test.
From the dome test, JAC 590R (t = 1.6 mm), JAC 780 TRIP (thickness = 1.0 mm)
and Al 6022 (t = 1.0 mm) are tested. Lubrication system is developed from the
dome test. With lubrication system, samples are evaluated how much they deviate
from the apex of the dome by having percentage error they have in the flow stress
curve.
ii
Dedication
iii
Acknowledgements
Thanks God, I barely finish my study without Your help and Your strength that
comes from You. To be able to accomplish this study, I have been supported and
supervised by many people that God sent to me. To my family, I cannot express
my gratitude enough. I am indebted to my family and my friends who helped me a
lot during my school period. I believe that I would not be able to name everyone
separately and to thank for everything that they did for me, however, I would like
to express a few words of thanks from the bottom of my heart. I would like to
express my deepest gratitude to:
Prof. Taylan Altan for his great support and his valuable suggestions which make
me strong to step up beyond my deficiency. His intellectual support, advice and
guidance make me possible to accomplish this research works. I thank my
committee member Dr. Jerald Brevick for support.
I thank my colleagues of the CPF, Eren Billur, Dr. Hyun-Sung Son, Soumya
Subramonian, Tingting Mao, Xi Yang, Adam Groseclose, Niranjan Rajagopal for
their assistance. I also want to express great thanks to HRA, Jim Dykeman and
Ben Flocken for their support.
Specially, I would like to thank my parents and my sister for their endless
encouragement, inspiration, advice and support.
I would like to thank all those too numerous to mention here, who have assisted
and encouraged to complete of my work.
iv
Vita
Hanyang University
Department of Mechanical
University
Fields of Study
v
Table of Contents
Abstract ................................................................................................................... ii
Acknowledgements ................................................................................................ iv
Vita.......................................................................................................................... v
7.3.2 VPB test vs. Dome test from DEFORM and PAMSTPMP... 51
vii
7.5.1 Preliminary Evaluation Lubricant Test .................................. 55
REFERNECES ..................................................................................................... 68
viii
List of Tables
1) ........................................................................................................................... 47
ix
List of Figures
2011] ....................................................................................................................... 4
Figure 3. The schematic of the force vs. elongation curve obtained from tensile
Figure 4. Engineering stress vs. engineering strain curve [Kalpakjian 2008] ........ 7
Figure 5. Comparison stress vs. strain curve between engineering state and true
Figure 6. True stress and true strain curve of Al 1100-O, plotted on log-log scale
Figure 7. Some of the flow curve equations used in plastic deformation studies
[Marciniak 2002, Altan 2012]: (a) Hollomons Law, (b) Swifts Law, (c) Linear
Figure 8. Predicted flow stress curves by different equations [Nasser 2010, Paul
2012] ..................................................................................................................... 10
x
Figure 10. Flow stress curve obtained from tensile test and bulge test [Billur
2011] ..................................................................................................................... 13
Figure 11. Sheet orientations relative to normal and planar anisotropy [Totten
Figure 12. Definitions of width and thickness strains in a tensile specimen [Davis
2004] ..................................................................................................................... 15
Figure 13. Schematic of Fukui conical cup test [Hosford 2007] .......................... 16
Figure 14. Schematic of Erichsen cup test [Doege 2010, Altan 2012] ................. 17
Figure 16. Location of maximum thinning when friction is (a) 0 and (b) 0.075
Figure 17. Influence of interface friction (a) on the location of maximum thinning,
Figure 18. Comparison of stretchability results of different steels from LDH test
Figure 20. Viscous Pressure Bulging (VPB) test set-up [Ngaile 2000] ................ 21
Figure 22. Fracture location of (a) frictionless dome test with fracture at apex,
TRIP 780 (t = 1mm) with lubrication (Teflon and Clay) (b) with no lubrication 24
Figure 23. Punch force vs. stroke curve of 780 TRIP. Fracture occurred at the
xi
Figure 24. Normalized punch force vs. stroke curve of 780 TRIP (t = 1.0mm) with
Figure 26. Schematic of the dome test [Grote 2009, Interlaken] .......................... 34
Figure 28. Punch force vs. stroke curve from experiment, 780 TRIP (t = 1.0 mm)
Figure 29. Top and front view of burst sample from dome test ( JAC 590R, t =
1.6mm) .................................................................................................................. 38
Figure 30. Punch force vs. stroke curve of JAC 590R (t = 1.6mm) ..................... 39
Figure 31. Punch force vs. stroke curve of 780 TRIP (t = 1.0mm) ...................... 40
Figure 32. Punch force vs. stroke curve of Al 6022 (t = 1.0mm) ......................... 40
Figure 35. PRODOME window to select experimental punch force vs. stroke data
............................................................................................................................... 44
Figure 36. PRODOME window to input initial thickness and normal anisotropy of
Figure 37. PRODOME window shows punch force vs. stroke curve from
experiment and buttons to renew data, initial thickness and/or normal anisotropy
............................................................................................................................... 45
Figure 38. PRODOME window that shows calculated flow stress curve ........... 46
xii
Figure 39. PRODOME window that shows buttons which can save data ........... 46
Figure 40. Flow stress curves of materials of JAC 590R, TRIP 780 and Al 6022
Figure 41. Comparison flow stress curve obtained from the dome test (isotropic,
anisotropic) and the tensile test for JAC 590R (t = 1.6 mm) ................................ 50
Figure 42. Comparison flow stress curve obtained from the dome test (isotropic,
anisotropic) and tensile test for JAC 780 TRIP (t = 1.6 mm) ............................... 51
Figure 43. Digitized punch force vs. stroke curve obtained from experiment ..... 52
Figure 44. Comparison K and n values among VPB test, DEFORM and
PAMSTAMP......................................................................................................... 53
Figure 45. (a) Punch force vs. stroke curve with good zero point adjustment and
shifted zero point adjustment (b) flow stress curve of good zero point adjustment
Figure 46. Reference sample of JSC 270F (t = 0.8 mm) for calibration, stroke up
to 1.00 inch............................................................................................................ 54
Figure 48. Dome test sample of JAC 780 TRIP (t = 1.6 mm) with lubricant of
Teflon and Clay of (a) sample 1, (b) sample 2 and (c) sample 3 .......................... 56
Figure 49. Measuring the angle of fracture using AutoCAD software (780 TRIP
Figure 50. Flow stress curve with angle of fractures for JAC 590R (t = 1.6mm) 59
xiii
Figure 51. Flow stress curve with angle of fractures for 780 TRIP (t = 1.0mm) . 59
Figure 52. Flow stress curve with angle of fractures for Al 6022 (t = 1.0mm) .... 60
Figure 53. Percentage error, maximum strain and the dome height on each angle
Figure 54. Percentage error, maximum strain and the dome height on each angle
Figure 55. Percentage error, maximum strain and the dome height on each angle
Figure 56. Angle of fracture with increasing friction (JAC 590R, t = 1.6 mm) ... 62
xiv
CHAPTER 1 INTRODUCTION
Uniaxial tensile test is a standard test which is commonly used by sheet material
suppliers/steel mills to determine the formability of sheet materials. The flow
stress curve obtained from the tensile test is under uniaxial state of stress which is
not enough to emulate the stress state in actual stamping. Another effect of this is
that true strain range obtained from the tensile test is limited because local
necking starts at the Ultimate Tensile Strength (UTS). Extrapolation of flow stress
data from the tensile test to obtain large strains is an approximation and not
accurate compared to the data from a biaxial test. Therefore, it is necessary to
conduct a biaxial test to obtain flow stress curve with a larger range of strain
compared to that of a tensile test.
1
The dome test is used to evaluate formability and flow stress curve of sheet
materials. The main reason of using the dome test instead of hydraulic bulge test
is the ease in conducting the dome test. With these benefits, companies may
prefer to conduct the dome test to obtain sheet material property. In this thesis, K
and n values are determined in Hollomons law (=Kn) from the output of the
dome test (punch force vs. stroke curve). Finite element based inverse analysis
technique [Cho 2005] is used to determine K and n values.
2
CHAPTER 2 BACKGROUND
3
2.1 Uniaxial Tensile Test
The uniaxial tensile test is the standard test to determine mechanical properties of
metals. As shown in Figure 1, standard size specimen is cut out from the sheet
metal and stretched slowly until it fractures.
Gage Length
l 0= 50.8mm (2 in)
Width = 12.7mm
Width = 19.1 mm (0.50 in)
(0.75 in)
Wider ends of the specimen are gripped by the special fixtures not influencing
deformation. The specimen is attached to fixed and moving crossheads as shown
in Figure 2. During the test, fixed crosshead is fixed and moving crosshead is
pulled down. Consequently, gripped specimen is pulled down and reaction forces
are applied on both sides of the specimen. Extensometer measures the elongation
of gage length in real time. Through the test, load vs. elongation curve is obtained
as shown in Figure 3. It is normalized with respect to the geometry of specimen to
calculate stress and strain. lU is uniform elongation and lF is total elongation at
load vs. elongation curve.
4
F
Column
Fixed Crosshead
Specimen
Moving Crosshead v
F
Table
Fracture
Load (F)
Force
Uniform
Plastic
Deformation
Non-uniform
Plastic
lU Deformation
lF
Elongation
Elongation (l)
Figure 3. The schematic of the force vs. elongation curve obtained from tensile
test [Altan 2012]
5
Engineering stress ( ) is defined as the force (F) divided by the original cross-
Eq. 1
Eq. 2
where is the original length of the gage and is the elongation. As illustrated
in Figure 4, there is useful information in engineering stress vs. engineering strain
curve. Yield strength (Y or ) is the stress value where elastic phase finishes.
After yield strength, plastic phase starts. Yield strength can be determined by any
three of these techniques: (a) offset method, (b) Extension under load method, (c)
Autographic diagram method [ASTM 2011]. For elastic phase, linear slope
indicates Youngs modulus (E). When engineering stress reaches maximum
engineering stress, specimen starts localized necking ending uniform elongation
( ), and the stress value at this point is called ultimate tensile strength (UTS or
). Uniform elongation ( ) is considered to be an indicator of ductility or
formability of the material because after necking, material starts to fail [Altan
2012]. Engineering stress and engineering strain are based on original cross-
sectional area. However, true stress (or flow stress, ) is the ratio of applied load
(F) and instantaneous cross-section area (A) as shown in Eq. 3 [Altan 2012].
Eq. 3
6
Figure 4. Engineering stress vs. engineering strain curve [Kalpakjian 2008]
Eq. 4 shows how true stress (flow stress) is derived from engineering stress and
engineering strain [Marciniak 2002]. True strain is calculated by considering
instantaneous gage length (l) divided by initial length of the gage ( ) as shown in
Eq. 5.
Eq. 4
Eq. 5
7
According to the definition of true stress and true strain curve, flow stress curve
can be drawn up to the strain of b which corresponds to the ultimate tensile
strength (UTS) at the engineering stress and engineering strain curve as shown in
Figure 5.
Relationship between stress and strain can be expressed with Hookes Law
( ) in elastic region and Hollomons Law in plastic region (=Kn). In
elastic region, stress and strain have linear relationship. Youngs modulus (E) can
be determined by the slope of the engineering stress ( ) and engineering strain (e)
curve. In the plastic region, Hollomons Law is the most commonly used
nonlinear relationship between true stress and true strain. K indicates the strength
coefficient and n is the strain hardening exponent. Figure 6 shows the true stress
and true strain curve of Al 1100-O [Hosford 2007, Altan 2012].
Figure 5. Comparison stress vs. strain curve between engineering state and true
state [Hosford 2007]
8
10000
I II III
1
0.0001 0.001 0.010 0.100 1.00
True Strain,
Figure 6. True stress and true strain curve of Al 1100-O, plotted on log-log scale
[Hosford 2007, Altan 2012]
Flow stress curve is the curve after yield stress and before plastically necking.
Flow stress is important in metal forming processes as it defines the behavior of
material deformation. It is a function of strain ( ) , strain rate ( ) , temperature ( )
and microstructure (S) as shown in Eq. 6.
f , , , S Eq. 6
In most materials, flow stress increases with strain in room temperature because
of strain hardening which is a result of interaction of dislocations or inclusions in
the crystalline structure [Lange 1985]. Flow stress curve equations are developed
in different ways as shown in Figure 7. Including Hollomons Law which is a
good approximation of the flow stress curve [Phlandt 1989], there are several
other equations which are shown in Figure 8.
9
Figure 7. Some of the flow curve equations used in plastic deformation studies
[Marciniak 2002, Altan 2012]: (a) Hollomons Law, (b) Swifts Law, (c) Linear
strain hardening, and (d) Constant
Figure 8. Predicted flow stress curves by different equations [Nasser 2010, Paul
2012]
Flow stress curve from tensile test is generally preferred because of its simplicity
and the conditions of tensile test have been well defined by standards [Phlandt
1989]:
10
ASTM E 6-09b: Standard Definitions of Terms Relating to Methods of
Mechanical Testing, 2009
ASTM E8/E8M-11: Standard Test Methods for Tension Testing of
Metallic Materials 2011.
ASTM A 370: Standard Methods and Definitions for Mechanical Testing
of Steel Products, 2012
ASTM B 557: Standard Methods of Tension Testing Wrought and Cast
Aluminum and Magnesium Alloy Products, 2010
ASTM B 557M: Standard Methods of Tension Testing of Wrought and
Cas Aluminum and Magnesium Products (Metric), 2010
ISO 6892: Metallic materials Tensile testing Part 1: Method of test
at room temperature - First Edition, 2009
Euronorm 2-80: Tensile Testing on Steel (Revision), 1980
ASTM E83 REVa: Standard Practice for Verification and Classification
of Extensometers, 2010
ASTM E 1012: Standard Practice for Verification of Testing Frame and
Specimen Alignment Under Tensile and Compressive Axial Force
Application, 2012
However, there is a demand for another test method to determine flow stress
curve for metal forming purposes. In practice, strain hardening exponent (n) is
considered as an indication of material formability since it corresponds to the
value of uniform elongation in the engineering stress and engineering strain curve.
The necking (instability in tensile test) starts when normal force (F) is at the
condition of maximum and this can be formulated by Eq. 7.
dF
0 Eq. 7
d
11
Right before reaching maximum force, the normal force can be expressed as
shown in Eq. 8.
d
exp exp
dF
0 A0 Eq. 9
d d
d
d
Therefore, tensile instability condition is obtained by Eq. 10 when the flow stress
is assumed to follow Hollomons Law.
d
nK n 1 K n Eq. 10
d
or:
Figure 9 illustrates true stress and true strain condition at necking in tensile test.
For most of the metals, strain hardening exponent lies in the range of 0.1 to 0.5
[Phlandt 1989], tensile test can only determine flow stress curve for a small
range of strain as shown in Figure 10.
12
K n
d
Slope
d 1
1000
Effective Stress ( ) [MPa]
800
Bulge Test
_
600
400
Tensile Test
200
DP 600, t = 1.0mm
0
0 0.1 0.2 0.3 0.4 0.5
Effective Strain ( )
Figure 10. Flow stress curve obtained from tensile test and bulge test [Billur
2011]
As a result, the widely used tensile test has deficiencies [Altan 2012]:
13
It gives material properties for uniaxial conditions while in practical
errors.
On the other hand, tensile test can be useful to determine anisotropy properties. In
real world, microstructures of the materials are not always uniform in all
directions (isotropic) but are aligned in certain directions (anisotropic). It is
important to get anisotropy coefficients of the sheet material. Anisotropy can be
defined by two forms: (1) normal anisotropy, and (2) planar anisotropy. As shown
in Figure 11, while normal anisotropy differs through the thickness of the material,
planar anisotropy changes according to various directions within the plane of the
sheet [Altan 2012].
Normal
Anisotropy Planar
(r) r0
Anisotropy
r45 r
r90
Rolling
Direction
Figure 11. Sheet orientations relative to normal and planar anisotropy [Totten
2003, Altan 2012]
While sheet metal is processed, grains of the materials microstructure are aligned
in rolling direction and packed in thickness direction. This leads to significant
differences in strength properties in rolling direction and perpendicular to
14
rolling direction. Ratio of the strains in the width to thickness directions
determined by tensile test is referred to as r-value, also known as the plastic strain
ratio. It is given by Eq. 11 where w is the width strain and t is the thickness
strain, as illustrated in Figure 12.
w
r Eq. 11
t
t
Figure 12. Definitions of width and thickness strains in a tensile specimen [Davis
2004]
With higher r values, sheet material tends to resist to thinning. The plastic strain
ratio (r) is determined along parallel ( ), transverse ( ) and diagonal ( ) to
rolling direction of the sheet material. Normal anisotropy ( ) and planar
anisotropy ( ) are defined as shown in Eq. 12 and Eq. 13 [Phlandt 1989, Altan
2012].
Eq. 12
r0 2r45 r90
r Eq. 13
2
15
2.2 Biaxial Tension Test
2.2.1 Cupping tests
There are several cupping tests to determine formability, such as Swift cup test,
Fukui test, and Erichsen test. From Swift cup test, limiting drawing ratio for the
flat bottom cups is determined. Fukui conical cup test as illustrated in Figure 13
determines both stretching and drawing over a spherical indenter [Hosford 2007].
16
Figure 14. Schematic of Erichsen cup test [Doege 2010, Altan 2012]
Hecker proposed Limiting Dome Height (LDH) Test to avoid the small area of
deformation which was one of the limitations of the Erichsen cup test, and Ghosh
modified Hecker test to simulate plane-strain condition where 80% of stamping
failure occurs [Ayers 1979]. LDH test uses 101.6 mm (4) diameter of the punch
and sheet material is stretched in biaxial directions while clamped at the edges by
lockbead to avoid draw-in (Figure 15). At ERC/NSM, the LDH test was used to
evaluate lubricants. FE simulations for the LDH test showed that the test is very
sensitive to friction and it affect the test measurements [Ngaile 1999]. FE
simulations, shown in Figure 16, are conducted to study relationships of interface
friction. As expected maximum thinning when friction is zero occurred at the
apex of the dome. For friction of 0.075, location of maximum thinning shifted by
20 mm away from the apex [Ngaile 2000, Hosford 2007, Altan 2012].
17
Figure 15. Schematic of LDH tooling [Grote 2009]
Generally, location of maximum thinning moves away from the apex of the dome
as interface friction increases, and punch force also increase as interface friction
increases as shown in Figure 17.
(a) (b)
Figure 16. Location of maximum thinning when friction is (a) 0 and (b) 0.075
[Ngaile 2000]
18
Y 30 1.2
25 1
54
15
Y 0.6 52
51
10 0.4
Hemispherical 50
5 punch 0.2
49
0 0.02 0.04 0.06 0.08 0.1
0 0
0 0.02 0.04 0.06 0.08 0.1
X Coefficient of friction
Coefficient of friction
(a) (b)
Figure 17. Influence of interface friction (a) on the location of maximum thinning,
(b) on punch force [Ngaile 2000]
Figure 18 shows limiting dome height of several materials which indicates each
materials stretchability.
Figure 18. Comparison of stretchability results of different steels from LDH test
[WSA 2009, Altan 2012]
19
LDH test can simulate the most critical strain state in plane strain conditions, so it
is usually used in industry. However, there are several limitations for using LDH
test [Narasimham 1995]:
Large scatter of results from LDH test needed special detailed procedure
recommended by North American Deep Drawing Research Group
(NADDRG) [ASM/NADDRG 1987]. Despite the special procedure, it is
nearly impossible to reproduce the results within a laboratory and between
different laboratories [ASM/NADDRG 1990].
It is hard to obtain stable reproducible plane-strain condition over large
region of the sheet material.
Result is dependent critically upon small variations in plastic anisotropy,
friction and constraint of the drawbead [Ghosh 1975].
It is time consuming.
There is imprecise definition of failure because of nature of the crack
[Narasimham 1995].
In bulge test, sheet material is deformed under balanced biaxial deformation while
it is clamped around its periphery (Figure 19). There are two types of bulge test:
(a) hydraulic bulge test using pressurized fluid (such as oil) and (b) Viscous
Pressure Bulge test using viscous medium as shown in Figure 20.
20
Figure 19. Schematic of Hydraulic Bulge Test [Gutscher 2004]
Figure 20. Viscous Pressure Bulging (VPB) test set-up [Ngaile 2000]
21
parameters for die sets are initial sheet material thickness ( , clamping force ( ),
upper die fillet radius ( ), die cavity radius ( ).
Eq. 14
Eq. 15
Eq. 16
To calculate effective strain ( ), measured parameters, which are pressure (P) and
dome height ( ), need to be determined and there are several methods such as
Hill [Hill 1950], Enikeev-Kruglov [Kruglov 2002, Slota 2008] and Chakrabarty-
Alexander. In a recent study, Slota showed that the result from Enikeev-Kruglov
approach is more accurate than that of Hill approach [Slota 2008].
22
Since bulge test is applied to a thin sheet material (i.e., , where is
die cavity diameter), membrane theory can be assumed in which bending effects
are negligible [Hill 1950, Ranta 1979, Gutscher 2004, Billur 2008]. Based on von
Mises yield criterion, the effective stress can be calculated by Eq. 17 [Gutscher
2004].
Eq. 17
There are some limitations with using hydraulic bulge test as follows [Young
1981, Ko 2011, Altan 2012]:
This test has not been standardized so that it is difficult to compare results
from different tooling and laboratories.
Tooling gets dirty after sheet bursts because of using oil or viscous
medium.
It is highly demanding time and labor to analyze the data from the test.
23
2.2.4 Dome Test (extension of LDH test)
Using same tooling of LDH test (Figure 15), dome test can be utilized to
determine flow stress, formability and anisotropy for stamping under biaxial
deformation condition. It should be noted that adequate lubrications (near zero
friction) are needed to obtain flow stress accurately. Maximum thinning occurs at
the apex of the dome when friction is zero as in the bulge test as shown in Figure
22(a). Friction at tool-workpiece interface has an effect on formability and
thinning distribution. As friction increases, maximum thinning location moves
toward die corner radius as shown in Figure 22 (b).
By using dome test, it may be possible to determine (a) flow stress under biaxial
deformation, (b) formability under biaxial stretch and (c) a flow stress equation in
Hollomons Law (=Kn) that provide reliable input data on mechanical
properties of sheet materials to generate FE simulations of metal flow in stamping.
(a) (b)
Figure 22. Fracture location of (a) frictionless dome test with fracture at apex,
TRIP 780 (t = 1mm) with lubrication (Teflon and Clay) (b) with no lubrication
24
CHAPTER 3 OBJECTIVES AND APPROACH
3.1 Objectives
Overall objective is to determine flow stress curves (determining K and n values
in Hollomons law, =Kn ) of sheet metal, by using the dome test which is easier
to use in industry than the bulge test. There are two parts to satisfy overall
objective:
1) Experiments:
2) Inverse Analysis:
3.2 Approach
1) Phase 1: Conduct preliminary experiments for evaluation of the lubricants
for dome tests at Honda R&D.
a. Punch force and punch stroke are recorded during dome test.
25
1mm). Hydro-Aluminums suggestion is to achieve a nearly
friction-less state making 7 layer system. This sample is our
reference model for making FE simulations. Recorded punch force
vs. stroke curve from experiment is shown in Figure 23.
200
100
50
0
0 10 20 30 40 50
Stroke [mm]
Final punch stroke
from exp.= 37.5 mm
Figure 23. Punch force vs. stroke curve of 780 TRIP. Fracture occurred at the
apex of the dome
Simulations were conducted for constant K and several n values by using tool
geometry provided by Interlaken and punch force will be calculated as a function
of punch stroke as described below:
26
a. The material model is assumed to be following Hollomon law
(Power law) =Kn where K is strength coefficient and n is strain
hardening exponent.
b. n affects the shape of the punch force vs. punch stroke curve.
c. However, K does not affect the shape of the punch force vs. punch
stroke curve but affects the magnitude of the punch force vs. punch
stroke curve. Thus, the FE simulations will be conducted for a
preselected K value and various n values (K = 1000MPa, n =
0.060.6 with 0.01 increments).
Eq. 18
27
Where:
K= Eq. 19
Where,
28
b. Tensile test is conducted for anisotropy coefficient (r0, r45 and r90)
by Honda.
Eq. 20
Eq. 21
Where, =
29
CHAPTER 4 INVERSE ANALYSIS METHODOLOGY
Inverse analysis methodology was used to determine the flow stress and the
interface friction at elevated temperatures by [Cho 2003]. Following procedure is
the inverse analysis methodology applied to this study:
1) The data points on experimental punch force vs. stroke curve were
provided by Honda.
3) After obtaining punch force vs. stroke curves from experiments and FE
simulations, each curve was normalized by dividing the force at various
stroke positions by the punch force at the maximum experimental stroke
(Figure 24). Normalization of the punch force vs. stroke curve on both
experiment and FE simulation was done to eliminate the effect of K on the
magnitude of the punch force vs. stroke curve. n value only affects the
shape of the punch force vs. stroke curve.
5) K does not affect shape of the punch force vs. punch stroke curve but
affects the magnitude of the punch force vs. stroke curve. Since FE
30
simulations were done with K = 1000 MPa, K value can be calculated by
Eq. 19. Since initial thickness of FE simulation model was 1 mm,
maximum punch force from FE simulation should be multiplied by initial
thickness. This is on approximation to be evaluated later.
1.0
0.8
Normalized Punch Force [kN]
0.6
0.4
0.2
780 TRIP (t = 1.0mm)
0.0
0 10 20 30 40 50
Stroke [mm]
Final punch stroke
from exp.= 37.5 mm
Figure 24. Normalized punch force vs. stroke curve of 780 TRIP (t = 1.0mm) with
fracture at the apex of the dome
31
Initial guess of K (1000 MPa) and n (0.06)
Run FE simulations
with several n values
(n = 0.06 to 0.6)
Extract FE simulation
results
Store Difference ( )
No
n = 0.6 ?
Yes
Find minimum
Determine n value
32
CHAPTER 5 EXPERIMENTAL WORK AND RESULTS
33
6.35 mm 0.25 in.
The dome test experiments were done with the tooling described in the previous
section. The press used for these experiments is a 150 ton press manufactured by
Interlaken as shown in Figure 27.
At the beginning, the tooling is open and the sheet material is placed between die
and blankholder. When the press runs, the sheet is clamped by lockbead. Then the
solid hemispherical punch moves upward and deforms the sheet. As a result of
high clamping force and lockbead, the sheet is prevented from drawing into die
cavity. The sheet is deformed until it fractures.
With the computer controlled system, it is possible to record punch force, punch
stroke, clamp force and clamp stroke with time. From this data acquisition, punch
force vs. stroke curve can be made, and this curve is needed to determine flow
stress curve of the material.
34
Camera system
Die
Blank
holder UniTest control
system
In the dome test, punch force and punch stroke were recorded by the computer
controlled system. Since the punch force vs. stroke curve is invalid after the sheet
fractures, the data has to be deleted after fracture. Punch force vs. stroke curve is
plotted shown as Figure 28. From punch force vs. stroke curve, dome height (AC)
and maximum punch force also can be detected.
35
200
Max. punch force
=150 kN Dome height
(distance AC)
Reference
150
B
Punch Force [kN]
100
50
Figure 28. Punch force vs. stroke curve from experiment, 780 TRIP (t = 1.0 mm)
with lubricants of Teflon and Clay
36
Table 2. Material properties evaluated by tensile test provided by Honda
Al 6022-
Parameter Unit JSC 270F JAC 590R 780 TRIP
T4
In Table 3, the parameters for the dome test are shown. The speed of the punch is
set to 1.35 mm/s (0.06 in/sec). The clamping force of 445 kN (100,000 lbs) and
lockbead ensured that the sheet is not drawn into the die cavity. The test specimen
is square of 165.1 mm 165.1 mm (6.5 in 6.5 in). Figure 29 shows a burst
sample of JAC 590R. The best location of the fracture is the apex of the dome to
have frictionless condition. Lubricant system will be discussed in more detail in
Section 7.5. The ring mark around the sample is formed by lockbead.
37
Table 3. Test parameters of the dome test
Figure 29. Top and front view of burst sample from dome test ( JAC 590R, t =
1.6mm)
38
5.5 Test Results
From experiments, punch force vs. stroke curve of three materials (JAC 590R,
780 TRIP, Al 6022) are obtained. Fracture occurred at the apex of the dome by
eliminating or minimizing the friction (combination of Teflon and Clay as
lubricants). Punch force vs. stroke curves are shown in Figure 30, 31 and 32.
Since, fracture did not occur at the apex of the dome for JSC 270F (t = 0.8mm)
and JAC 780 TRIP (t = 1.6 mm), the results are not included.
200
100
50
0
0 10 20 30 40 50
Stroke [mm] Final punch stroke
from exp.= 43.1 mm
Figure 30. Punch force vs. stroke curve of JAC 590R (t = 1.6mm)
39
200
50
0
0 10 20 30 40 50
Stroke [mm]
Final punch stroke
from exp.= 37.5 mm
Figure 31. Punch force vs. stroke curve of 780 TRIP (t = 1.0mm)
200
Al 620 (t = 1.0mm)
150
Punch Force [kN]
100
50
Max. punch force
=40 kN
0
0 10 20 30 40 50
Stroke [mm] Final punch stroke
from exp.= 35.7 mm
40
CHAPTER 6 FE SIMULATIONS
41
Sheet
Die
Blankholder
Punch
The flow stress of the sheet material can be described by the Hollomons Law:
Eq. 22
42
6.2 Computer Program PRODOME Using MATLAB
6.2.1 General concepts of computer program using MATLAB
Computer program
Experimental Normalize punch force vs. stroke
punch force vs. curve Determine K & n
According to experimental stroke, values and
stroke curve calculate difference between exp.
(Excel File) normalized punch force and
normalized FE punch force
Determine n value that brings
minimum difference between exp. and
simulation
Calculate K value
Consider initial thickness ( )
Consider anisotropy correction
FE simulation
database
(PAMSTAMP)
43
6.2.2 Running the PRODOME
When the PRODOME is run, it asks to open an Excel file with the experimental
punch force vs. stroke data as shown in Figure 35.
Figure 35. PRODOME window to select experimental punch force vs. stroke data
Once the punch force vs. stroke data is copied from the Excel file, the
PRODOME will ask for the initial thickness ( ) and normal anisotropy ( ) of the
sheet material as shown in Figure 36.
As shown in Figure 37, once all the parameters are entered, the punch force vs.
stroke curve is plotted on the upper right side of the screen. Punch force vs. stroke
data, initial thickness and normal anisotropy can be changed by clicking the
relevant buttons.
By clicking the yellow Calculate Stress Strain button, the PRODOME
inversely calculates K and n values, and the maximum strain. Flow stress is
plotted on the lower right side as shown in Figure 38.
44
As shown in Figure 39, true stress and true strain data can be saved in Excel file
by clicking the button below the true stress and true strain table. Plots can also be
saved by clicking the buttons.
Figure 36. PRODOME window to input initial thickness and normal anisotropy of
the sheet material
Figure 37. PRODOME window shows punch force vs. stroke curve from
experiment and buttons to renew data, initial thickness and/or normal anisotropy
45
Figure 38. PRODOME window that shows calculated flow stress curve
Figure 39. PRODOME window that shows buttons which can save data
46
CHAPTER 7 RESULTS AND DISCUSSION
JAC 590R
955 0.30 0.72
(t = 1.6mm)
TRIP 780
1335 0.28 0.54
(t = 1.0mm)
Al 6022
348 0.20 0.53
(t = 1.0mm)
47
1400
JAC 590R (t=1.6mm)
TRIP 780 (t =1.0mm)
1200
Al 620 (t=1.0mm)
1000
800
600
200
K = 348 MPa, n = 0.20
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
True strain
Figure 40. Flow stress curves of materials of JAC 590R, TRIP 780 and Al 6022
with isotropic assumption ( = 1)
48
Hill 1990, Nasser 2010, Billlur 2011]. Normal anisotropies are calculated for the
materials as shown in Table 5.
Flow stress curves obtained from the dome test and tensile test were compared as
shown in Figures 41 and 42. Flow stress curves obtained from the dome test were
anisotropy corrected as discussed in Section 7.2. Since tensile test result of Al
49
6022 (t = 1.0 mm) was not available, flow stress curve comparison could not be
made for Al.
1400
Dome test w/o anisotropy
1200 Dome test w anisotropy
Tensile test
800
600
K = 955 MPa, n = 0.30, = 0.72
400
K = 984 MPa, n = 0.18, = 0.15
200
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
True Strain
Figure 41. Comparison of flow stress curves obtained from the dome test
(isotropic, anisotropic) and the tensile test for JAC 590R (t = 1.6 mm)
50
1400
Dome test w/o anisotropy
Dome test w anisotropy
1200
Tensile test
1000
True Stress [MPa]
400
K = 1507 MPa, n = 0.26, = 0.15
200
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
True Strain
Figure 42. Comparisons flow stress curves obtained from the dome test (isotropic,
anisotropic) and tensile test for JAC 780 TRIP (t = 1.6 mm)
7.3.2 VPB test vs. Dome test from DEFORM and PAMSTAMP
In a preliminary study on the dome test, JAC 270E (t = 0.69 mm) was used for
sheet material[Demiralp 2011]. In the report, K and n values were determined by
conducting FE simulation using DEFORM. K and n values from VPB test was
also reported on this report. To calculate K and n values from the PRODOME
(based on PAMSTAMP), 10 digitized points of punch force vs. stroke curve
(Figure 43) (experimental dome test) were used as input to the PRODOME. Table
6 describes each K and n values from VPB test, DEFORM and PAMSTAMP.
51
Figure 43. Digitized punch force vs. stroke curve obtained from dome test
experiment (JAC 270E)
PAMSTAMP
Parameters VPB test [MPa] DEFORM [MPa]
[MPa]
52
800
VPB test
700 DEFORM K = 711 MPa, n = 0.25
PAMSTAMP
600
True Stress [MPa]
500
K = 680 MPa, n = 0.25
400
200
100
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
True Strain
Figure 44. Comparison K and n values among VPB test, DEFORM and
PAMSTAMP
53
200 1200
good zero point adjustment (A)
shifted zero point adjustment (B)
1000
A
150
K = 955 MPa, n = 0.30
800
400
50
0 0
0 10 20 30 40 50 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
(a) (b)
Figure 45. (a) Punch force vs. stroke curve with good zero point adjustment and
shifted zero point adjustment (b) flow stress curve of good zero point adjustment
and shifted zero point adjustment
To extablish a good method to make a zero point adjustment, one test was done
by stopping the punch at 1 inch before fracture occurred at the sample of JSC
270F (t = 0.8 mm) as shown in Figure 46. Dome height (AC from Figure 28) was
measured with height gage. The zero point on the experimental load vs. stroke
curve was determined, i.e., measured AC on the sample and maximum stroke on
the load vs. stroke curve were equal.
Figure 46. Reference sample of JSC 270F (t = 0.8 mm) for calibration, stroke up
to 1.00 inch
54
7.5 Lubrication System
To obtain the flow stress curve accurately, maximum thinning should occur at the
apex of the dome as in the VPB test. However, fracture does not occur always at
the apex of the dome in the dome test. When friction exists, maximum thinning
occurs away from the apex of the dome as shown in Figure 47. Therefore, it is
necessary to know how much angle of the fracture ( in Figure 47) is acceptable
to use the flow stress curve obtained from the dome test. In this Section,
percentage error between reference sample (of which fracture occurred at the apex)
and other samples are calculated.
In these dome tests, various lubricants were used to eliminate the friction between
the punch and the sheet. Lubricants applied to the experiments are described in
APPENDIX A.
55
For JSC 270F (t = 0.8 mm), samples were tested with a number of combinations
of lubricants listed in APPENDIX B. However, all samples showed fracture far
from the apex. For a different way to obtain fracture at the apex, punch stroke was
stopped after some distance and lubricants were renewed. This procedure also
could not help to obtain fracture at the apex of the dome (APPENDIX B). Dome
height and maximum punch force did not much change after renewing lubricants.
Also, for JAC 780 TRIP (t = 1.6 mm), fracture did not occur at the apex of the
dome with the same lubrication condition that caused fracture at the apex for
other thickness (t = 1.0 mm) and other materials (JAC 590R and Al 6022). as
shown in Figure 48 .
Figure 48. Dome test sample of JAC 780 TRIP (t = 1.6 mm) with lubricant of
Teflon and Clay of (a) sample 1, (b) sample 2 and (c) sample 3
To measure the angle of fracture from the apex, Figure 49, AutoCAD software
was used. After the photo of a sample is taken from front side as in Figure 49, it
56
was exported to AutoCAD and the radius was measured. Ruler was set together
beside of the sample to obtain absolute radius of the dome.
Fracture
Figure 49. Measuring the angle of fracture using AutoCAD software (780 TRIP
with no lubrication, t = 1.0 mm)
Eq. 23
where l is curvature length from the apex of the dome to the fracture, and r is
radius of the dome. r is measured by making 3 points circle fit of the sample in
Auto CAD. Reference samples for each material are considered to be used as
follows:
57
JAC 780 TRIP (t = 1.0 mm) with lubricants of Hydro Aluminums
suggestion (7 layer system conceiting of lanolin/Teflon
foil/lanolin/Mipolam (2 mm thick)/lanolin/Teflon foil/lanolin),
Angle of the fractures of the reference samples were measured to be smaller than
2 degrees. Average percentage error of the flow stress curve is calculated by using
Eq. 24:
Eq. 24
where i corresponds to the strain with increment of 0.01 until maximum strain
( ) of either reference flow stress ( ) or objective flow stress ( ). Flow
stress curve with different angles of fracture for each material are shown in
Figures 50, 51 and 52. Lubrication system which contains percentage error at the
angle where fracture occurred, maximum strain and dome height are shown in
Figures 53, 54 and 55.
58
1400
AB
CD
1200
1000 D
400
A: fracture at 2 deg.
B: fracture at 12 deg.
200 C: fracture at 16 deg.
D: fracture at 46 deg.
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
True Strain
Figure 50. Flow stress curve with angle of fractures () for JAC 590R (t = 1.6mm)
1400
D
AB C 1200 A
D EF
1000 B, C
G
True Stress [MPa]
800
600
400
A: fracture at 2 deg.
B: fracture at 5 deg.
200 C: fracture at 7 deg.
D: fracture at 12 deg.
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
True Strain
Figure 51. Flow stress curve with angle of fractures () for 780 TRIP (t = 1.0mm)
59
400
AB
C
300
A, B, C
100
A: fracture at 2 deg.
B: fracture at 5 deg.
C: fracture at 38 deg.
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
True Strain
Figure 52. Flow stress curve with angle of fractures () for Al 6022 (t = 1.0mm)
0.8 50
AB Maximum Strain
Dome Height
CD
40
0.6
20
0.2
10
0.0 0
A B C D
(2 deg.) (12 deg.) (16 deg.) (46 deg.)
Figure 53. Percentage error, maximum strain and the dome height on each angle
of fracture () for JAC 590R (t = 1.6mm)
60
0.8 50
Maximum Strain
Dome Height [mm]
AB C
D EF 0.6
40
Max. Strain
0.4
20
Reference 6 %
0.2
7% 10 % 8% 22 % 21 %
error error error error error error 10
0.0 0
A B C D E F G
(2 deg.) (5 deg.) (7 deg.) (15 deg.) (20 deg.)(47 deg.) (49 deg.)
Figure 54. Percentage error, maximum strain and the dome height on each angle
of fracture () for 780 TRIP (t = 1.0mm)
0.8 50
Maximum Strain
AB Dome Height
C 40
0.6
0.4
20
0.2
Reference 0.6 % error 2 % error 10
0.0 0
A B C
(2 deg.) (5 deg.) (38 deg.)
Figure 55. Percentage error, maximum strain and the dome height on each angle
For JAC 590R (t = 1.6 mm), simulations were conducted with different
coefficient of friction (0.050.35 with 0.05 increments). For K and n values for
flow stress curve to input, 955 MPa and 0.30 are used as same as the reference
61
sample of JAC 590R has. Punch stroke was up to 35.6 mm to obtain coefficient of
friction in dry condition (46 degree of angle of fracture shown in Figure 53). At
maximum thinning distribution, the location of maximum thinning (possible
fracture) could be predicted. Angle of fracture were calculated by using same
methodology which were used for measurement of angle of fractures on
experimental samples.
Minimum angle
Maximum angle
(a)
50
46.2
43.8
42.1
40 40.4 41.4 40.4
Angle of Fracture [deg.]
39.8
36.4 38.0
34.2
30 30.0
27.9
20
17.4
15.2
10
0
0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
Coefficient of Friction
(b)
Figure 56. Angle of fracture from apex () with increasing friction (JAC 590R, t =
1.6 mm) (simulations)
62
Because of element size, minimum angle of fracture and maximum angle of
fracture were calculated as shown in Figure 56 (a). In Figure 56 (b), angle of
fracture are described as a function of coefficient of friction. In this result, JAC
590R sample in dry condition (46 deg.) has coefficient of friction approximately
of 0.35 (Figure 56 (b)).
63
CHAPTER 8 SUMMARY, CONCLUSIONS AND FUTURE WORK
Obtaining and using precise material property is important for designing stamping
process. Only accurate inputs to FE simulations give reliable outputs. The dome
test is a material test for sheet materials to evaluate formability and determine the
flow stress curve. Since the stress state of the dome test is biaxial, the maximum
achievable strain without localized necking is much larger than that of the tensile
test.
In this study, inverse analysis methodology was used to obtain flow stress curves
(assumed to be following Hollomons Law: ) from punch force vs.
stroke curves of the tested sheet materials. (JAC 590R (t = 1.6 mm), JAC 780
TRIP (t = 1.0mm) and Al 6022 (t = 1.0 mm)). From experiments, punch force vs.
stroke curves were recorded. PRODOME was developed using MATLAB with
database obtained from FE simulations (K = 1000 MPa, n = 0.06 ~ 0.6 with 0.01
increments). By running the PRODOME, K & n and maximum plastic strain
( ) can be determined. Also, lubrication system was investigated when
friction cannot be eliminated.
Fracture did not occur at the apex of the dome of JSC 270F (t = 0.8mm).
For future work, it is desirable to try with combination of lubricants of
beef tallow which is oil that performs high viscosity, and urethane. It is
reported that lubricant causes fracture to occur at the apex of the dome for
both mild steel and high strength steel. Garbage bag can also be
considered to try to be used as lubricant.
With the same lubricants which successfully worked for JAC 780 TRIP (t
= 1.0mm), the thicker material (JAC 780T, t=1.6mm) did not give the
64
fracture at the apex because friction stress which is dependent on interface
pressure is higher for thicker material. (Coulombs law, Friction stress ( )
= Coefficient of friction ()*Pressure (p)).
In comparison of the flow stress curve between the tensile test and the
dome test, flow stress curve for JAC 590R gets closer to the flow stress
curve from the tensile test. For JAC 780 TRIP, flow stress curve did not
change much after anisotropy correction.
In a sample of 1.6mm thick JAC 590R, the flow stress curve determined
by the dome test with anisotropy correction was up to a true strain of 0.64,
whereas by the tensile test, it was up to 0.15. For sample of 1.0mm thick
JAC 780 TRIP, the flow stress curve determined by the dome test with
anisotropy correction was up to a true strain of 0.53, whereas by the
tensile test, it was up to 0.15.
The flow stress curve obtained from the VPB test, was compared with the
dome test analysis using DEFORM and using PAMSTAMP. The flow
stress curve from PAMSTAMP follows well the result from VPB test
(average 1% error). Between the VPB test and the dome test using the
DEFORM, average error is approximately 5%.
65
The Dome Test allows, under biaxial deformation, the determination of:
(a) the flow stress curve up to larger strains compared to the tensile test
and (b) formability under biaxial stretch.
Lubricants of Teflon + Clay reduce friction well for JAC 780T (t=1.0mm),
JAC 590R (t=1.6mm) and Al 6022 (1.0 mm) and they are easy to use
compared to Hydro Aluminums suggestion.
66
This study attempted to investigate the errors introduced when the fracture
occurred away from the apex. However, more work is needed with other
sheet materials to establish guidelines for the proper used of the dome test.
67
REFERENCES
Altan, T., Oh, S., and Gegel, H. L., Metal Forming: Fundamentals and
Applications, American Society for Metals, (1983).
ASTM A 370: Standard Methods and Definitions for Mechanical Testing of Steel
Products, (2012).
ASTM E 1012: Standard Practice for Verification of Testing Frame and Specimen
Alignment Under Tensile and Compressive Axial Force Application, (2012).
Ayers, R. A., Brazier, W.G. and Sajewski, V. F., J. Appl. Metal working,
1,(1979).
Billur, E. and Ko, M., " a Comparative Study on Hydraulic Bulge Testing and
Analysis Methods ", Proceedings of the 2008 International Manufacturing
Science and Engineering Conference, (2008).
68
Billur, E., et al., Factor Affecting the Accuracy of Flow Stress Determined by the
Bulge Test, Steel Research Journal, (2011).
Davis, J.R., Tensile Testing, 2nd Edition, ASM International. ISBN 0-87170-806-
X, (2004).
Demiralp, Y., et al., Determination of Flow Stress by using Dome Test and
Finite Element Based Inverse Analysis Preliminary Study, CPF report-
2.1/11/01, (2011).
Gutscher, G., Wu, H., Ngaile, G., and Altan, T., Determination of flow stress for
sheet metal forming using the viscous pressure bulge (VPB) test, Journal of
Materials Processing Technology Vol.146, pp.1-7, (2004).
69
Hill, R., A Theory of the yielding and plastic flow of anisotropic metals,
Proceedings of the Royal Society of London, 193A, p.281-297, (1948).
Hosford, W.F. and Caddell, R.M.. Metal Forming: Mechanics and Metallurgy, 3rd
Edition, Cambridge University Press . ISBN 978-0-521-88121-0., (2007).
ISO 6892: Metallic materials Tensile testing Part 1: Method of test at room
temperature - First Edition, (2009).
Kaya, S., T. Altan, T., Groche, P., Klpsch, C.,: Determination of the flow stress
of magnesium AZ31-O sheet at elevated temperatures using the hydraulicbulge
test, International Journal of Machine Tools & Manufacture 48 550-557., (2008).
Lange, K., ed. Handbook of Metal Forming, McGraw-Hill, New York , (1985).
Marciniak, Z., J.L. Duncan and S.J. Hu. Mechanics of Sheet Metal Forming,
Butterworth Heinemann ISBN 0-7506-5300-0, (2002).
Nasser, A., Yadav, A., Pathak, P., Altan, T., Journal of Materials Processing
Technology 210 429436., (2010).
Ngaile, G., Altan, T. Model Test to Evaluate Lubricants and Die coatings in Tube
Hydroforming, Report No. THF/ERC/NSM-99-R-4, (1999).
70
Paul, S.K., "Predicting the flow behavior of metals under different strain rate and
temperature through phenomenological modeling", Computer Materials Science
65 , p. 91-99, (2012).
Ranta-Eskola, A. J.: Use Of The Hydraulic Bulge Test In Biaxial Tensile Testing,
Int. J. of Mech. Sciences 21 p.457-465., (1979).
Slota, J., Spik, E.: Determination of Flow Stress by the Hydraulic Bulge Test,
Metalurgija 47, (2008).
71
APPENDIX A: Lubricants list
Lanolin (sheep wool fat/wax spray type) from TriState Distributors, Inc
(Product info: http://tsdnetwork.com/Fluid-Film.php)
Mipolam Elegance 290/ 0131 Opal (2mm thick) from Gerflor North
America (Product info: http://www.gerflor.com/int/floors-for-
professionals/product-page/mipolam-elegance-290,8.html)
557 Silicon: Dow Corning Silicone Dry Film 557 (Product info:
http://www.firstpowergroupllc.com/DCC_Product_Sheets/Molykote_557.
pdf)
72
APPENDIX B: Evaluation lubricant tests for high formability material (JSC
270F, t = 0.8 mm)
Max. Max.
sam
Lube Punch Punch
ple pic note
condition force Stroke
#
[lbs] [inch]
Fracture
1 557Si+Gr 15899 1.432
557Si+Teflo
n+557Si+Ru
2 bber2+557Si 16455 1.64 Fracture
+Teflon+557
Si
Fracture
3 557Si 15972 1.441
Fracture
4 557Si 16212 1.471
73
5 2 layered Fracture
16215 1.622
Teflon
Necking
6 Dry 15449 1.399
Fracture
9 Lanolin 15900 1.443
74
ME290 - Fracture
10 2.05mm 16323 1.335
thick
Punch is
covered
11 Punch
15077 1.402
Teflon Fracture with
Teflon.
Fracture
12 Rubber1+Cl
16827 1.673
ay
Rubber1+Te Necking
13 17886 1.616
flon+Clay
14 Rubber1+Te Fracture
16951 1.651
flon+clay
75
Rubber1+Ru
15 bber2+Teflo 17288 1.619 Fracture
n+Clay
Fracture
16 Teflon 16862 1.652
19 Teflon-Clay-
16654 1.648 Fracture
557Si
76
Different punch stroke
Max.
sam Max.
Lube Punch
ple Punch pic note
condition Stroke
# force [lbs]
[inch]
Out of
Teflon +
1 center of
Clay
punch
reference
sample for
Teflon + calibration
2 N/A N/A
Clay of 2 stage
up to
1.00"
2stage:
3
Teflon +
16077 1.759
Fracture 1.0''
Clay stop/failur
e
Teflon + Fracture
4 16468 1.761 non stop
Clay
Teflon + Fracture
5 15414 1.472 non stop
Clay
2stage:
6
Teflon +
15899 1.779 Fracture 1.2''
Clay stop/failur
e
77
3stage:
Teflon +
12 15758 1.723 Fracture 1.00''/1.4''/
Clay
failure
78