docSheet Metal Forming I
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Sheet Metal Forming I
Sheet Metal Forming I Prof. Dr.-Ing. Dr.-Ing. E.h. F. Klocke Simulation Techniques in Manufacturing © WZL/Fraunhofer IPT The Audi A2 Aluminum Spaceframe casting profile sheet metal Source: Schuler © WZL/Fraunhofer IPT Seite 1 Principle of flat-strip rolling © WZL/Fraunhofer IPT Seite 2 Principle of tensile test for sheet metals © WZL/Fraunhofer IPT Seite 3 Schematic diagram of flat upsetting test © WZL/Fraunhofer IPT Seite 4 Hydraulic bulge test © WZL/Fraunhofer IPT Seite 5 Flow curve and strain hardening exponent n © WZL/Fraunhofer IPT Seite 6 Definition of anisotropy © WZL/Fraunhofer IPT Seite 7 Dependency of corner accumulation on flat anisotropy © WZL/Fraunhofer IPT Seite 8 Calculation of strains from a deformed measuring grid © WZL/Fraunhofer IPT Seite 9 Forming limit diagram © WZL/Fraunhofer IPT Seite 10 Test for the determination of the friction value © WZL/Fraunhofer IPT Seite 11 Deep drawing of a flat blank © WZL/Fraunhofer IPT Seite 12 Forming of a blank © WZL/Fraunhofer IPT Seite 13 Stresses during deep-drawing © WZL/Fraunhofer IPT Seite 14 Deformation of a volume element © WZL/Fraunhofer IPT Seite 15 Drawing tool with a retaining bulge in the drawing ring © WZL/Fraunhofer IPT Seite 16 Principle of ironing © WZL/Fraunhofer IPT Seite 17 Multilevel ironing tool © WZL/Fraunhofer IPT Seite 18 Ironing depending on the distance of the ironing rings © WZL/Fraunhofer IPT Seite 19 Deep drawing with electric discharge or explosive detonation © WZL/Fraunhofer IPT Seite 20 Process of deep drawing of "Tailored Blanks" © WZL/Fraunhofer IPT Seite 21 Deep drawing defects © WZL/Fraunhofer IPT Seite 22 Principle of collar drawing © WZL/Fraunhofer IPT Seite 23 Stress state in collar drawing © WZL/Fraunhofer IPT Seite 24 Press for stretch drawing © WZL RWTH Aachen 2002 © WZL/Fraunhofer IPT Seite 25 Advantage of using tangential drawing © WZL/Fraunhofer IPT Seite 26 Tool for stretch drawing of aeroplane wing parts Source: MBB © WZL/Fraunhofer IPT Seite 27 Combination of stretch drawing and deep drawing process © WZL/Fraunhofer IPT Seite 28 Neutral fibre in bending and stretch drawing © WZL/Fraunhofer IPT Seite 29 Possible failures in stretchdrawing © WZL/Fraunhofer IPT Seite 30 Forces in stretch drawing © WZL/Fraunhofer IPT Seite 31 Spin operation (schematical) withSpin intermediate stages © WZL/Fraunhofer IPT Seite 32 Aluminum reflectors Source: Leifeld & Co. © WZL/Fraunhofer IPT Seite 33 Spinning processes © WZL/Fraunhofer IPT Seite 34 Manufacturing defects during spinning of a cup shaped workpiece © WZL/Fraunhofer IPT Seite 35 Force components in spinning © WZL/Fraunhofer IPT Seite 36 NC-controlled spin- and counter roll © WZL/Fraunhofer IPT Seite 37 Laser assisted spinning © WZL/Fraunhofer IPT Seite 38 Bending process © WZL/Fraunhofer IPT Seite 39 Definition of the springback factor © WZL/Fraunhofer IPT Seite 40 Different dies for bending in the V - die © WZL/Fraunhofer IPT Seite 41 U-form bending in die with and without counter punch © WZL/Fraunhofer IPT Seite 42 Principle of sway-folding © WZL/Fraunhofer IPT Seite 43 Corrugating © WZL/Fraunhofer IPT Seite 44 Production of a channel section © WZL/Fraunhofer IPT Seite 45 Position of rolls in loop forming machine © WZL/Fraunhofer IPT Seite 46 Special shapes in roll bending © WZL/Fraunhofer IPT Seite 47 Bending die with tool frame © WZL/Fraunhofer IPT Seite 48 Examples for die bending sequences © WZL/Fraunhofer IPT Seite 49 Pivot bending machine and profiles © WZL/Fraunhofer IPT Seite 50 Internal tube hydroforming © WZL/Fraunhofer IPT Seite 51 Achievable shapes in tube hydroforming © WZL/Fraunhofer IPT Seite 52 Tube hydroforming press and hydroformed automobile frame part source: Schuler-Hydroforming © WZL/Fraunhofer IPT Seite 53 Rear axle of the Audi TT with three hydroformed parts Lower support Main support Transverse control arm Source: Audi © WZL/Fraunhofer IPT Seite 54 Tube hydroforming: Engine support THF tool Engine frame with mounted parts Comparison with conventional design: 30 % less weight 20 % cheaper 60 % less tool cost © WZL/Fraunhofer IPT Seite 55 Tube hydroforming: Movie „Engine Support“ (6 min 30 sec) Source: Schuler-Hydroforming © WZL/Fraunhofer IPT Seite 56 Work diagram for expantion (after Dohmann) © WZL/Fraunhofer IPT Seite 57 More influence-largely on the result of working © WZL/Fraunhofer IPT Seite 58 Transform force and internal pressure as a function of wall thickness © WZL/Fraunhofer IPT Seite 59 Tool design in tube hydroforming © WZL/Fraunhofer IPT Seite 60 Vacuum forming of a hollow body © WZL/Fraunhofer IPT Seite 61 Principle of laser bending © WZL/Fraunhofer IPT Seite 62 Principle of magnetic forming © WZL/Fraunhofer IPT Seite 63 Compression of tubulary shaped components by magnetic forming © WZL RWTH Aachen 2002 © WZL/Fraunhofer IPT Seite 64 Magnetic closing of milk bottles © WZL/Fraunhofer IPT Seite 65
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