Temperature conditions during 'cold' sheet metal stamping

This paper investigates the friction and deformation-induced heating that occurs during the stamping of high strength sheet steels, under room temperature conditions. A thermo-mechanical finite element model of a typical plane strain stamping process was developed to understand the temperature conditions experienced within the die and blank material; and this was validated against experimental measurements. A high level of correlation was achieved between the finite element model and experimental data for a range of operating conditions and parameters. The model showed that the heat generated during realistic production conditions can result in high temperatures of up to 108 °C and 181 °C in the blank and die materials, respectively, for what was traditionally expected to be 'cold' forming conditions. It was identified that frictional heating was primarily responsible for the peak temperatures at the die surface, whilst the peak blank temperatures were caused by a combination of frictional and deformation induced heating. The results provide new insights into the local conditions within the blank and die, and are of direct relevance to sheet formability and tool wear performance during industrial stamping processes. © 2014 Elsevier B.V. All rights reserved.

On the definition of an kinematic hardening effect graph for sheet metal forming process simulations

The objective of this work is to develop a kinematic hardening effect graph (KHEG) which can be used to evaluate the effect of kinematic hardening on the model accuracy of numerical sheet metal forming simulations and this without the need of complex material characterisation. The virtual manufacturing process design and optimisation depends on the accuracy of the constitutive models used to represent material behaviour. Under reverse strain paths the Bauschinger effect phenomenon is modelled using kinematic hardening models. However, due to the complexity of the experimental testing required to characterise this phenomenon in this work the KHEG is presented as an indicator to evaluate the potential benefit of carrying out these tests. The tool is validated with the classic three point bending process and the U-channel width drawbead process. In the same way, the capability of the KHEG to identify effects in forming processes that do not include forming strain reversals is identified.

Roll-formability of cryo-rolled ultrafine aluminium sheet

Ultrafine-grain aluminium sheet was produced by rolling at cryogenic (CR) and at room temperature (RTR). Commercial purity aluminium plate was reduced in 30 passes from an initial material thickness of 10 mm to a final thickness of 2 mm (80% reduction). Tensile stress and strength were significantly increased while total elongation was drastically reduced. It was found that despite the low tensile elongation both materials are able to accommodate high localised strains in the neck leading to a high reduction in area. The formability of the material was further investigated in bending operations. A minimum bending radius of 6 mm (CR) and 5 mm (RTR) was found and pure bending tests showed homogeneous forming behaviour for both materials. In V-die bending the cryo-rolled material showed strain localisations across the final radius and kinking of the sample. It has been found that even if the total elongation in tension is close to zero leading to early failure in V-die bending, ultra-fine grained and low ductile sheet metals can be roll formed to simple section shapes with small radii using commercial roll forming equipment.