Formability Training Dec2012 PDF

Fundamentals of Sheet Metal Formability
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Table of Contents
TABLE OF CONTENTS
TABLE OF CONTENTS 1
CHAPTER 1: TEST YOUR SHEET METAL FUNDAMENTALS 2
CHAPTER 2: PRESENTATIONS 7
Section 1: Manufacture and Processing of Sheet Metals 8
Section 2: Determination of the Mechanical Properties of Sheet Metal 18
Section 3: Basic Modes of Deformation in Stamping 30
Section 4: Defects in Stamping 41
Section 5: Tests of Formability 46
Section 6: Press Actions 66
Section 7: Basics of Draw Die Development 79
Section 8: Advanced Forming Processes and Technologies 91
Section 9: Revew: State-of-the-art in Forming Simulation Technology 99

Chapter 1: Test your Sheet Metal Fundamentals
Chapter 1
Test your Sheet Metal
Fundamentals
In This Chapter:
• Quiz
Test your Sheet Metal Fundamentals
1) What is the definition of Steel?
a) Alloy of Iron and Carbon b) Alloy of Aluminum and Carbon

c) Alloy of Tungsten and Carbon d) Alloy of Nickel & Cadmium
2) What does DQSK Steel stand for?
a) Draw Quality Special Killed b) Draw Quantity Simple King

c) Design Quality Steel Killed d) None of the above
3) If a member is subjected to a force of ‘F’, across a section of area ‘A’, the amount
of engineering stress in the member is:
a) F/A b) F*A
c) A/F d) None of the above
4) If the initial length of a member is L and it undergoes an elongation of ‘l’, the

engineering strain ‘e’ is:
a) l/ L b) l/(L-l)
c) L*l d) L*(L-l)
5) In the above example, how would you compute the ‘true’ strain from engineering
strain ‘e’?
a) 1+e b) ln (1+e)
c) ln (e) d) ln (e-1)
6) If the total strain is ‘e’ and the plastic’ strain is ‘ep’, what is the value of the elastic
strain ‘ee’?
a) ep – 1 b) ep * e
c) e – ep d) None of the above
7) Luders Bands appear where?
a) After the Yield point b) Before Yield point

c) At Failure d) After Failure
8) Higher strain ratio ‘r’ implies ability to draw:
a) More deeply b) Less deeply

c) No effect d) Cannot draw
9) In steels, generally, the higher the value of the yield, the hardening exponent ‘n’ is:
a) Higher b) Lower
c) Same d) No effect
10) In the Forming Limit Diagram (FLD), the X and Y axis represent respectively:
a) Major and Minor Strain b) Minor and Major Strain

c) Major and Minor Stress d) Minor and Major Stress
11) Points above the FLC in the FLD diagram indicate:
a) Safe zones b) Failure due to splitting

c) Wrinkles d) Marginal Failure due to splitting
12) The lower the Young’s modulus of the material, the:
a) Greater is springback b) Lower is the spring back

c) No change d) Cannot say
13) Tip Angle of the die influences which of these?
a) Initial Contact b) Draw depth

c) None d) All of the above
14) Addendum is defined as the portion:
a) Around the part b) Inside the part

c) Around the drawbead d) On the press
15) Draw Bars are used to control the:
a) Unequal length of line b) Flow of the material

c) Blank shape d) Binder tonnage
16) Metal Gainers are used in:
a) Stretch flanging operation b) Shrink flanging operation

c) Trimming d) None of the above
17) In mechanical presses the maximum tonnage occurs:
a) At TDC b) Remains the same throughout

c) At BDC d) Between the TDC and BDC
18) Which is true?
a) Hydraulic Presses are slower b) Hydraulic Presses can attain higher

than Mechanical Presses loads
c) Hydraulic Presses can give
constant tonnage throughout the d) All of the above
stroke
19) Superplastic forming is done under:
a) Elevated temperature b) At very low temperatures

c) Very high tonnage d) None of the above
20) Wrinkling can be observed in one step simulation by looking at the:
a) Thinning percentage b) Major and Minor Strains

c) FLD Contour d) All of the above
21) To do incremental analysis, the user requires:
a) Die Data b) Blank size and properties

c) Process conditions d) All of the above
Chapter 2: Presentations
Chapter 2
Presentations
In This Chapter:
• Manufacture and processing of sheet metals

• Determination of the mechanical properties of sheet metal
• Basic modes of deformation in stamping
• Defects in stamping
• Tests of Formability
• Press Actions
• Basics of Draw Die Development
• Advanced Forming Processes and Technologies
• Review State-of-the-art in Forming Simulation Technology
Section 1: Manufacture and Processing of Sheet Metals

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Section 2: Determination of the Mechanical Properties of Sheet

Metal
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Section 3: Basic Modes of Deformation in Stamping

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Section 4: Defects in Stamping

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Section 5: Tests of Formability

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Section 6: Press Actions

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Section 7: Basics of Draw Die Development

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Section 8: Advanced Forming Processes and Technologies

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Section 9: Revew: State-of-the-art in Forming Simulation Technology

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Fundamentals of Sheet Metal Formability

Altair Engineering Contact Information

FTP site Address: ftp.altair.com or ftp2.altair.com or http://ftp.altair.com/ftp

Location Telephone e-mail

The following countries have distributors for Altair Engineering:

Trademark and Registered Trademark Acknowledgments

CHAPTER 1: TEST YOUR SHEET METAL FUNDAMENTALS 2

Section 2: Determination of the Mechanical Properties of Sheet Metal 18

Section 3: Basic Modes of Deformation in Stamping 30

Section 4: Defects in Stamping 41

Section 5: Tests of Formability 46

Section 6: Press Actions 66

Section 7: Basics of Draw Die Development 79

Section 8: Advanced Forming Processes and Technologies 91

Section 9: Revew: State-of-the-art in Forming Simulation Technology 99

Test your Sheet Metal Fundamentals

1) What is the definition of Steel?

a) Alloy of Iron and Carbon b) Alloy of Aluminum and Carbon

2) What does DQSK Steel stand for?

a) Draw Quality Special Killed b) Draw Quantity Simple King

4) If the initial length of a member is L and it undergoes an elongation of ‘l’, the

7) Luders Bands appear where?

a) After the Yield point b) Before Yield point

8) Higher strain ratio ‘r’ implies ability to draw:

a) More deeply b) Less deeply

a) Major and Minor Strain b) Minor and Major Strain

11) Points above the FLC in the FLD diagram indicate:

a) Safe zones b) Failure due to splitting

12) The lower the Young’s modulus of the material, the:

a) Greater is springback b) Lower is the spring back

13) Tip Angle of the die influences which of these?

a) Initial Contact b) Draw depth

14) Addendum is defined as the portion:

a) Around the part b) Inside the part

15) Draw Bars are used to control the:

a) Unequal length of line b) Flow of the material

16) Metal Gainers are used in:

a) Stretch flanging operation b) Shrink flanging operation

17) In mechanical presses the maximum tonnage occurs:

a) At TDC b) Remains the same throughout

18) Which is true?

a) Hydraulic Presses are slower b) Hydraulic Presses can attain higher

19) Superplastic forming is done under:

a) Elevated temperature b) At very low temperatures

20) Wrinkling can be observed in one step simulation by looking at the:

a) Thinning percentage b) Major and Minor Strains

21) To do incremental analysis, the user requires:

a) Die Data b) Blank size and properties

• Manufacture and processing of sheet metals

Section 1: Manufacture and Processing of Sheet Metals

Section 2: Determination of the Mechanical Properties of Sheet

Section 3: Basic Modes of Deformation in Stamping

Section 4: Defects in Stamping

Section 5: Tests of Formability

Section 6: Press Actions

Section 7: Basics of Draw Die Development

Section 8: Advanced Forming Processes and Technologies

Section 9: Revew: State-of-the-art in Forming Simulation Technology

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