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Stamping and sheet metal forming
Abhinesh Bhuvanesh
1. the article overview
stamping is a kind of plastic forming process in which a part is produced bu means of the plastic forming the material under the action of a die. Stamping is usually carried out under cold state,so it is also called stamping .Heat stamping is used only when the blank thickness is greater than 8~100mm. the blank material for stamping is usually in the form of sheet or strip, and therefore it is also called sheet metal forming . some non-metal sheets (such as plywood, micasheet, asbestos, leather )can also be formed by stamping.
Stamping is widely used in various fields of the metalworking industry, and it plays a crucial role in the industries for manufacturing automobiles , instruments, military parts and household electrical appliances, etc.
The process, equipment and die are the three foundational problems that needed to be studied in stamping.
The characteristics of the sheet metal forming are as follows:
(1) High material utilization
(2) Capacity to produce thin-walled parts of complex shape.
(3) Good interchangeability between stamping parts due to precision in shape and dimension.
(4) Parts with lightweight, high-strength and fine rigidity can be obtained.
(5) High productivity, easy to operate and to realize mechanization and automatization.
The manufacture of the stamping die is costly, and therefore it only fits to mass production. For the manufacture of products in small batch and rich variety, the simple stamping die and the new equipment such as a stamping machining center, are usually adopted to meet the market demands.
The materials for sheep metal stamping include mild steel, copper, aluminum, magnesium alloy and high-plasticity alloy-steel, etc.
Stamping equipment includes plate shear punching press. The former shears plate into strips with a definite width, which would be pressed later. The later can be used both in shearing and forming.
2. Characteristics of stamping forming
There are various processes of stamping forming with different working patterns and names. but these processes are similar to each other in plastic deformation. There are following conspicuous characteristics in stamping:
(1). The force per unit area perpendicular to the blank surface is not large but is enough to cause the material plastic deformation. It is much less than the inner stresses on the plate plane directions. In most cases stamping forming can be treated approximately as that of the plane stress state to simplify vastly the theoretical analysis and the calculation of the process parameters.
(2). Due to the small relative thickness, the anti-instability capability of the blank is weak under compressive stress. As a result, the stamping process is difficult to proceed successfully without using the anti-instability device (such as blank holder). Therefore the varieties of the stamping processes dominated by tensile stress are more than dominated by compressive stress.
(3). During stamping forming, the inner stress of the blank is equal to or sometimes less than the yield stress of the material. In this point, the stamping is different from the bulk forming. During stamping forming, the influence of the hydrostatic pressure of the stress state in the deformation zone to the forming limit and the deformation resistance is mot so important as to the bulk forming. In some circumstances, such influence may be neglected. Even in the case when this influence should be considered, the treating method is also different form that of bulk forming.
(4). In stamping forming, the restrain action of the die to the blank is not severs as in the case of the bulk forming (such as die forging). In bulk forming, the constraint forming is proceeded by the die with exactly the same shape of the part. Whereas in stamping , in most cases, the blank has a certain degree of freedom, only one surface of the blank contacts with the die. In some extra cases, such as the forming of the blank on the deforming zone contact with the die.
The deformation in these regions are caused and controlled by the die applying an external force to its adjacent area.
Due to the characteristics of stamping deformation and mechanics mentioned above, the stamping technique is different form the bulk forming:
(1). The importance or the strength and rigidity of the die in stamping forming is less than that in bulk forming because the blank can be formed without applying large pressure per unit area on its surface. Instead, the techniques of the simple die and the pneumatic and hydraulic forming are developed.
(2). Due to the plane stress or simple strain state in comparison with bulk forming, more research on deformation or force and power parameters has been done. Stamping forming can be performed by more reasonable scientific methods. Based on the real time measurement and analysis on the sheet metal properties and stamping parameters, by means of computer and some modern testing apparatus, research on the intellectualized control of stamping process is also in proceeding.
(3). It is shown that there is a close relationship between stamping forming and raw material. The research on the properties of the stamping forming, that is, forming ability and shape stability, has become a key point in stamping technology development, but also enhances the manufacturing technique of iron and steel industry, and provides a reliable foundation for increasing sheet metal quality.
3.Categories of stamping forming
Many deformation processes can be done by stamping, the basic processes of the stamping can be divided into two kind: cutting and forming.
Cutting is a shearing process that one part of the blank is cut from the other. It mainly includes blanking, punching, trimming, parting and shaving, where punching and blanking are the most widely used. Forming is a process that one part of the blank has some displacement from the other. It mainly includes deep drawing, bending, local forming, bulging, flanging, necking, sizing and spinning.
In substance, stamping forming is such that the plastic deformation occurs in the deformation zone of the stamping blank caused by the external force. The stress state and deformation characteristic of the deformation zone are the basic factors to decide the properties of the stamping forming. Based on the stress state and deformation characteristics of the deformation zone, the forming methods can be divided into several categories with the same forming properties and be studied systematically.
The deformation zone in almost all types of stamping forming is in the plane stress state. Usually there is no force or only small force applied on the blank surface. When is assumed that the stress perpendicular to the blank surface equals to zero, two principal stresses perpendicular to each other and act on the blank surface produce the plastic deformation of the material. Due to the small thickness of the blank, it is approximately the two principal stresses distribute uniformly along the thickness direction. Based on this analysis, the stress state and the deformation characteristics of the deformation zone in all kinds of stamping forming can be denoted by the points in the coordinates of the plane principal stresses and the coordinates of the corresponding plane principal stresses and the coordinates of the corresponding plane principal strains.
3. Raw materials for stamping forming
There are a lot of raw materials used in stamping forming, and the properties of these materials may have large difference. The stamping forming can be succeeded only by determining the stamping method, the forming parameters and the die structures according to the properties and characteristics of the raw materials. The deformation of the blank during stamping forming has been investigated quite thoroughly. The relationships between the material properties decided by the chemistry component and structure of the material and the stamping forming has been established clearly. Not only the proper material can be selected based on the working condition and usage demand, but also the new material can be developed according to the demands of the blank properties during processing the stamping part. This is an important domain in stamping forming research. The research on the material properties for stamping forming is as follows:
(1). Definition of the stamping property of the material.
(2). Method to judge the stamping property of the material, find parameters to express the definitely material property of the stamping forming, establish the relationship between the property parameters and the practical stamping forming, and investigate the testing methods of the property parameters.
(3). Establish the relationship among the chemical component, structure, manufacturing process and stamping property.
The raw materials for stamping forming mainly include various metals and nonmetal plate. Sheet metal includes both ferrous and nonferrous metals. Although a lot of sheet metals are used in stamping forming, the most widely used materials are steel, stainless steel, aluminum alloy and various composite metal plates.
5.Stamping forming property of sheet metal and its assessing method
The stamping forming property of the sheet metal is the adaptation capability of the sheet metal to stamping forming. It has crucial meaning to the investigation of the stamping forming property of the sheet metal. In order to produce stamping forming parts with most scientific, economic and rational stamping forming process and forming parameters, it is necessary to understand clearly the properties of the sheep metal, so as to utilize the potential of the sheet metal fully in the production. On the other hand, to select plate material accurately and rationally in accordance with the characteristics of the shape and dimension of the stamping forming part and its forming technique is also necessary so that a scientific understanding and accurate judgment to the stamping forming properties of the sheet metal may be achieved.
There are direct and indirect testing methods to assess the stamping property of the sheet metal.
Practicality stamping test is the most direct method to assess stamping forming property of the sheep metal. This test is done exactly in the same condition as actual production by using the practical equipment and dies. Surely, this test result is most reliable. But this kind of assessing method is not comprehensively applicable, and cannot be shared as a commonly used standard between factories.
The simulation test is a kind of assessing method that after simplifying and summing up actual stamping forming methods, as well as eliminating many trivial factors, the stamping properties of the sheet metal are assessed, based on simplified axial-symmetric forming method under the same deformation stress states between the testing plate and the actual forming states. In order to guarantee the reliability and generality of simulation results, a lot of factors are regulated in detail, such as the shape and dimension of tools for test, blank dimension and testing conditions (stamping velocity, lubrication method and blank holding force, etc).
Indirect testing method is also called basic testing method its characteristic is to connect analysis and research on fundamental property and principle of the sheet metal during plastic deformation, and with the plastic deformation parameters of the sheep metal in actual stamping forming, and then to establish the relationship between the indirect testing results (indirect testing value ) and the actual stamping forming property (forming parameters). Because the shape and dimension of the specimen and the loading pattern of the indirect testing are different from the actual stamping forming, the deformation characteristics and stress states of the indirect test are different from those of the actual one. So, the results obtained forming the indirect test are not the stamping forming parameters, but are the fundamental parameters that can be used to represent the stamping forming property of the sheet metal. |
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