VISIT OUR SPONSORS ‘hms # magazine» 2018» ober 205 shat or assesng foming every The Science of Forming i HECHANGE Back Print Article ™ ‘aero Vet he eb 2015 sue uy Res swe GOH A SHORTCUT FOR ASSESSING FORMING SEVERITY Thore ae 1 commonts [Post a comment The forming-imit curve (FLC) tums 80 years old his year, Last month we reviewed some problems encountered when using the FLC to predict metaforming failure, While the appteation cetals may vary the basic analysis slope romain te same, 1) Apply a ico i o other strain racking process to the surface ofthe stamping. These markings wil etormine strain diroction, magnitude and gradient at desired locaton, in real or vival stampings 2) Deform the stamping tots fal form (Fg. 1), 5) At the locations of interest, measure the major stain =the largest postive stan or long ais ofthe alps, ‘ane then the minor stain—the axis perpendicular tothe major sain. 4 For low-carbon sets, generate the FLC (Fig. 2) using the thickness and workharcening exponent (1- value of the steel being formed to agust he height of the standard FLC cure, For nonferrous alloy, the FLC ‘shoul be gonerated inthe laboratory using ho canono nemisphericaldome less foreach cal 5) Plot the measured major and minor strains of the elipses (A,B,C) onthe FLC curve to assign 2 seventy rating (9.2). While his process can be time-consuming metalformers now can emplay cameralcomputer ants that fake before-anc-ater deformation photos | 7, ‘fink cts, spackle a oer patterns applied toa ‘workpiece. From these pictures, computers develop | gy the stan informaton.n FC (Fig 2) toa thexness ‘sain FLC (Fig. 3). This thicknoss FLC also lustrates grosn yllow and rod zones (safe, marginal and poiantal for alsres). Note th constant| «| tava ofthe FLC tthe lft ofthe cantertina tie connotes that all deformation witha negative minor | * 2 ‘Sain has the same thinning FLC. Those observing sa Setormaton n stampings incite that te greatest | 2 numbor of false occur in tho 10-pereent mnoe- ‘tan region. Stampings with larger positive minor ‘ain nol ony nave snereased major strain But leo have increased thinning without crossing into the red | «yaya faire zone, “an Sh Note: Thickness sain readings can rapidly be Fig 2—Tre FG (upporcune) seis he sin values whe onl of obtained with an ulrasoniothikness (UT) gauge, the loca ftrughinckres) neck, Tho ower curv represent th Poa ne thon plotted onto graphs (such as Fig. 3)for’ Pours of bon sto ane Asaf, B= immatiate severity determinationrigh localized deformation called stain gradionss |= ° + Sex (ig. 4), Localize stress causes deformation to Conceniate i one ave that usually has a large ‘malo surface stain and along porbondicular axis vit zore minor sain. For example, conser an ‘embossed character ine, Aste surface grant {roms with increasing major stain, the thickness of {he gradient mast decrease to comply withthe constancy-ofvolume rule. Often, gradients are ‘gored unil a tracture occurs. However, the Gradients easy are found in a stamping by using the UT gauge to sean potential areas. A high ‘magnitude of thinning shoul alert one toa potentalfalure zone requiring futher analysis ‘Why wait unl flues star during a production vn? Theses ala = Moe Suc Sin. * ‘Shootmetal bending i a Ile more complex. A pure Bed necator att ek eaune aay chanea he ig 3s rah canbe cola fom th tah Fi 2 ote te \workpiece-materal thickness. The tensile thinning _S>"an" Le rnezave minor sine ofthe outer aurface fs compensated by the compressive thickening ofthe inner surface, again cust the constancy- ‘bolum rule, Metaformers can refer to chats providing outer-er major sain Based onthe ratio of punch radius {(R) to material thickness (9, Compare this value tothe total elongation af the materal to determine relative seventy However, many times a tensile force is applied to te ends of the bend during forming. These forces cause stretch through the fllthickness ofthe sneet and add deformation tothe aver sraln, causing premature failure, The UT. ‘gauge can measure such extra thinning and add thal component tothe Rit sUotch rato obiaine from tho charts LUT gauges in metatorming applications can: 1) Deliver vary short measurement times, which allow for repeat measurements for improved accuracy. 2) Read thickness to 0.0001 in: 3) Be 10X more accurat (0.030.n. hick materat than eles stran for 4) Verity de setup conditions afte ci transition; 5) Find any deformation changes atthe end of @run to mark the ae for downtime comecton, Fig As etn 6) Monitor erica nonstable deformation areas ina wn stamping; and 7) Determine edge-centor-edge bickness ofa col without removing the banding MF ‘Stuart Kole and Peter Ulntz wil speak at PMA's Higher Strength Stoo! seminar on October 27-28 in Clavaland. OH. Related Enterprise Zones: MatrialsiCostngs READER COMMENTS Poste by Marv on 1412015 129020 PM fasatascfact POST A COMMENT ‘YOUR COMMENTS * (ow may use hn! fama) )tm not a robot > Submit PMA Series, ne Home Conse St