Forging and Sheet Metal Forming Automotive Production Engineer T. Udomphol by Dr. Tapany Udomphol School of Metallurgical Engineering Suranaree University of Technology Suranaree University of Technology September 2007 Forging and Sheet Metal Forming Outline Part I: Forging of Metals ( ) T. Udomphol • Introduction to metal forming • Hot and cold working • Deformation geometry • Classification of forging processes • Die design and die materials • Metal flow in forging • Force in metal forging • Forging defects Suranaree University of Technology September 2007 Forging and Sheet Metal Forming T. Udomphol Outline Part II: Sheet metal forming ( ) • Introduction to sheet metal forming • Sheet metal parts • Classification of sheet metal forming • Forming limit criteria • Defects in formed parts Suranaree University of Technology September 2007 T. Udomphol Introduction to metal forming Suranaree University of Technology September 2007 Introduction to metal forming There are a wide range of different metal parts involved in an automobile production. T. Udomphol www.designchain.com encarta.msn.com Suranaree University of Technology September 2007 Introduction to metal forming T. Udomphol Casting Metal processing Suranaree University of Technology Cutting i.e. i.e. Forming i.e. Joining i.e. • Gravity die casting • Pressure die casting • Centrifugal casting • Injection moulding • Rotational moulding • Electrochemical machining • Electrical discharge machining • Single/multiple point cutting • Grinding • Sheet metal forming • Forging • Rolling • Extrusion • Wire drawing • Fusion welding (arc, laser, electron beam) • Solid state welding (friction) •Mechanical joining September 2007 Classification of metal forming by subgroups T. Udomphol Metal forming Compressive forming Combined tensile and compressive forming Tensile forming •Rolling •Pulling through a die •Stretching •Open die forming •Deep drawing •Expanding •Closed die forming •Flange forming •Recessing •Indenting •Spinning •Pushing through a die •Upset bulging Suranaree University of Technology Forming by bending •Bending with linear tool motion •Bending with rotary tool motion Forming by shearing •Joggling •Twisting •Blanking •Coining September 2007 Introduction to metal forming T. Udomphol Forgings Forged wheels Suranaree University of Technology Forged aluminium pistons and connecting rods Hot forming product September 2007 Introduction to metal forming Net shape and metal powder forming products T. Udomphol Powder metal forming parts Sintered metal parts Metal injection moulding parts Net shape metal power parts Suranaree University of Technology September 2007 Introduction to metal forming Metal Sheet forming products T. Udomphol www.numerica-srl.it Electromagnetic forming of automotive parts www.mse.eng.ohio-state.edu Suranaree University of Technology Stamped plates September 2007 Introduction to metal forming T. Udomphol www.ducommunaero.com www.macri.it Forging machine Suranaree University of Technology September 2007 Hot and cold working T. Udomphol Working processes • The methods used to mechanically shape metals into other product forms. Hot working (0.6-0.8Tm) • Primary process • Recrystallisation Cold working (< 0.3Tm) • Secondary process • No recrystallisation Suranaree University of Technology September 2007 Annealing mechanisms in cold worked metals T. Udomphol • Mechanical properties change due to temperature after cold working Suranaree University of Technology September 2007 Annealing mechanisms in cold worked metals Properties T. Udomphol Ductility Strength Hardness Cold worked and recovered Recovery ~0.3Tm New grains Recrystallisation ~0.5Tm Temperature Grain growth Annealing mechanisms in cold worked metals Suranaree University of Technology September 2007 T. Udomphol Effects of grain size and strain on recrystallisation temperature Schematic of recrystallisation diagram Smaller grains Suranaree University of Technology Better strength/properties September 2007 T. Udomphol Effects of grain size and strain on recrystallisation temperature Flow stress of aluminium as a function of strain at different temperature Temp Flow stress Suranaree University of Technology Flow curves of Cu Zn28 Strain rate Flow stress September 2007 Advantages and disadvantages of hot and cold working Hot working T. Udomphol Advantages • Low flow stress + high ductility • Pore sealed up • Smaller grains • Softer metals Disadvantages • Surface oxidation • Poor dimensional control • Hot shortness • Difficult handling Suranaree University of Technology Cold working Advantages • Stronger • Good surface finish • Good dimensional control • Easy handling Disadvantages • High deformation • Reduced ductility • Expensive equipment September 2007 Deformation geometry Effect of principal stresses in metal working Biaxial-plane stress condition • Two principal stresses, 1 and • EX: Sheet metal forming 2. Triaxial-plane strain condition T. Udomphol • Three principal stresses, 1 , , where 1 > 2 > 3. • EX: Forging, rolling extrusion Suranaree University of Technology Biaxial 2 and Triaxial 3 September 2007 Part I: Forging of metals • Forging is the working of metal into a useful shape by hammering or pressing. T. Udomphol • Primitive blacksmith • Parts ranging in size of a bolt to a turbine rotor. • Most carried out hot, although certain metals may be cold-forged. www.eindiabusiness.com Suranaree University of Technology www.prime-metals.com September 2007 Classification of forging processes T. Udomphol By equipment 1) Forging hammer or drop hammer 2) Press forging By process 1) Open - die forging 2) Closed - die forging Suranaree University of Technology September 2007 T. Udomphol Forging machines Suranaree University of Technology September 2007 Forging machines T. Udomphol • The energy supplied by the blow is equal to the potential energy due to the weight of the ram and the height of the fall. Drop hammer Potential energy = mgh • Mass production (60-150 blow / min) • Dies are subject to impact loading Suranaree University of Technology September 2007 Forging machines T. Udomphol Hydraulic Press forging • Continuous forming at slower rate • Deeper penetration • Expensive equipment • Heat loss from workpiece (long contact) • Die life Suranaree University of Technology September 2007 Closed and open die forging T. Udomphol Open-die forging Closed-die forging Impression-die forging Suranaree University of Technology September 2007 T. Udomphol Open--die forging Open • Flat dies • Simple shape • Large objects. • Pre-forming Suranaree University of Technology September 2007 T. Udomphol Close--die forging (Impression forging) Close • Workpiece is formed under high pressure in a closed cavity. • Small components • Precision forging • Expensive die Suranaree University of Technology September 2007 Forging load T. Udomphol Die cavity completely filled Flash begins to form Dies contact workpiece Forging complete Forging load Forging stroke Typical curve of forging load vs. stroke for closed-die forging. Suranaree University of Technology Flash is the excess metal, which squirts out of the cavity as a thick ribbon of metal. September 2007 Functions of flash T. Udomphol The flash serves two purposes: • Acts as a ‘safety value’ for excess metal. • Builds up high pressure to ensure that the metal fills all recesses of the die cavity. Remark: It is necessary to achieve complete filling of the forging cavity without generating excessive pressures against the die that may cause it to fracture. Suranaree University of Technology September 2007 T. Udomphol Closed--die design Closed Considerations • workpiece volume and weight • number of preforming steps and their configuration • flash dimensions in preforming and finishing dies the load and energy requirement for each forging operation, for example; the flow stress of the materials, the fictional condition, the flow of the material in order to develop the optimum geometry for the dies. Suranaree University of Technology September 2007 T. Udomphol Shape classification Suranaree University of Technology September 2007 T. Udomphol Shape classification Suranaree University of Technology September 2007 Die set and forging steps for automobile engine connecting rod Preforming of a round piece in an open die arrangement. Rough shape is formed using a block die. Finishing die gives final tolerances and surface finish. Removal of flash (excess metal). T. Udomphol • • • • Steering knuckle Rail Flange http://www.hirschvogel.de/en/produkti onsverfahren/warmumformung.php See simulation Suranaree University of Technology September 2007 General considerations for preform design • Metal used = Metal preform + Flash. • Concave radii of the preform > radii on the final forging part. • Cross section of the preform should be higher and narrower than the T. Udomphol final cross section. draft angle web rib • Shapes with thin and long sections or projections (ribs and webs) are more difficult to process due to • higher surface area per unit volume • increasing friction • temperature effects. Some typical nomenclature Suranaree University of Technology September 2007 General considerations for preform design • Smooth metal flow – symmetry dies • Avoid shape change T. Udomphol • Minimum flash to do the job. • Tapered or drafted to facilitate removal of the finished piece. • Draft allowance is approximately 3-5o outside and 7-10o inside. • Counterlock to prevent side thrust. draft angle web rib Suranaree University of Technology Counterlock Side thrust September 2007 Die materials www.nitrex.com T. Udomphol Required properties • Thermal shock resistance • Thermal fatigue resistance • High temperature strength • High wear resistance • High toughness and ductility • High hardenability • High dimensional stability during hardening • High machinability Suranaree University of Technology Forging die Die materials: alloyed steels (with Cr, Mo, W, V), tool steels, cast steels or cast iron. (Heat treatments such as nitriding or chromium plating) 1) Carbon steels with 0.7-0.85% C are appropriate for small tools and flat impressions. 2) Medium-alloyed tool steels for hammer dies. 3) Highly alloyed steels for high temperature resistant dies used in presses and horizontal forging machines. September 2007 Die materials Forging materials T. Udomphol Forging dies Die inserts Steels Copper and copper alloys DIN AISI DIN AISI Light alloys DIN AISI C70 W2 - C85 W2 - 60MnSi4 - X30WCrV53 H21 X30WCrV53 - 40CrMnMo7 - X38CrMoV51 H11 X38CrMoV51 H11 X32CrMoV33 H10 55NiCrMoV6 6F2 55NiCrMoV6 56NiCrMoV7 6F3 56NiCrMoV7 6F2 57NiCrMoV77 - 35NiCrMo16 - X38CrMoV51 57NiCrMoV77 - 57NiCrMoV77 6F3 H11 X30WCrV93 H21 X38CrMoV51 H11 X32CrMoV33 H10 X32CrMoV33 H10 X32CrMoV33 H10 X30WCrV53 - X30WCrV52 - X30WCrV53 - X37CrMoW51 H12 Suranaree University of Technology September 2007 T. Udomphol Die life improvement Current forging Future forging To increase die life 1) Improving die materials such as using composite die or 2) Using surface coating or selflubricating coatings Ultra hard surface coatings • Improve die life. • Reduce energy input. • Reduce die-related uptime and downtime. http://www.eere.energy.gov/industry/supporting_industries /pdfs/innovative_die_materials.pdf Suranaree University of Technology • Reduce particulate emission from lubricants. September 2007 Die failures T. Udomphol Wear (abrasion) Thermal fatigue Mechanical fatigue Permanent deformation • Different parts of dies are liable to permanent deformation and wear resulting from mechanical and thermal fatigue Suranaree University of Technology September 2007 T. Udomphol Increasing reduction Metal flow in forging Deformation bands associated with plastic instability. Schematic representation of shear band formation in compression of a cylinder. Finite element analysis of upsetting an aluminium cylinder Suranaree University of Technology September 2007 T. Udomphol Metal flow in forging Grain structure resulting from (a) forging, (b) machining and (c) casting. Fibre structure in forged steels Suranaree University of Technology September 2007 Metal flow in forging T. Udomphol Metal flow in forging • Identify the neutral surface • Metal flows away from the neutral surface in a direction perpendicular to the die motion. Suranaree University of Technology September 2007 Metal flow in forging Cold forging Step II Step III Step IV T. Udomphol Step I • Forging of nut and bolt www.qform3d.com Suranaree University of Technology September 2007 Metal flow in forging Cold forging • Forging of nut and bolt Step II Step III T. Udomphol Step I www.qform3d.com Suranaree University of Technology September 2007 Metal flow in forging T. Udomphol Hot forging Titanium alloy being forged at 930oC to produce preliminary turbine blade pre-form. http://www.qform3d.com/en/59.html Suck in flaw www.qform3d.com Suranaree University of Technology September 2007 Metal flow in forging •AISI 1040 being forged from a square bar at 1200oC to produce a shaft. T. Udomphol Hot forging • Extensive metal flow into flash • Incomplete fill up at the upper part www.qform3d.com Suranaree University of Technology September 2007 Metal flow in forging • DIN/C43 being forged from a round bar at 1250oC to produce a shaft fork. T. Udomphol Hot forging • Possible die filling with minimum flash used. www.qform3d.com Suranaree University of Technology September 2007 Metal flow in forging Forging from compact bar T. Udomphol www.qform3d.com • Powder compact bar of 0.78 density being forged. • The density increases first in the intermediate area then spread throughout the cross section. Suranaree University of Technology September 2007 Forces in metal forging Friction between two surfaces T. Udomphol F i Ar i P pAr p …Eq.1 Where = frictional coefficient = the shearing stress at the interface P = the load normal to the interface F = the shearing force Ar= summation of asperity areas in contact p = the stress normal to the interface Suranaree University of Technology September 2007 Forces in metal forging T. Udomphol The calculation of forging load can be considered in three cases 1. No friction 2. Small friction 3. Sticky friction Suranaree University of Technology September 2007 No friction Do T. Udomphol ho h P oA Where P D Do2 ho D 2 h ….Eq. 2 is the compressive force is the yield stress of the metal is the cross sectional area of the metal. o A 4 o Ah 4P 4 Ph p 2 2 D Do ho Do2 ho Suranaree University of Technology ….Eq. 3 September 2007 Small friction T. Udomphol • Small friction (homogeneous forging) • Assumption: - no barrelling - small thickness, Then - frictional conditions on the top and bottom faces of the disk are a constant coefficient of Coulomb friction; Suranaree University of Technology p …Eq.4 Where = frictional coefficient = the shearing stress at the interface p = the stress normal to the interface September 2007 Small friction • Small friction (non-homogeneous forging) Pmax Friction hill T. Udomphol X=0 X=a P o -a h a X Functions of a metal working lubricant P Suranaree University of Technology - Reduces deformation load - Increases limit of deformation before fracture - Controls surface finish - Minimises metal pickup on tools - Minimises tool wear - Thermally insulates the workpiece and the tools - Cools the workpiece and/or tools September 2007 Small friction Forging stress 2 y exp a x h T. Udomphol ' o 2 a h y o' exp Friction hill 2 a x h o' exp ….Eq. 5 Average forging pressure ‘o a -a X a p o' 1 ….Eq. 6 h _ a/h Forging pressure Suranaree University of Technology x = -a x=0 x=a September 2007 High friction (Sticky friction) Forging stress ax 1 h T. Udomphol y o' a h y o' 1 ….Eq. 7 ax 1 h o' Friction hill ‘o Average forging pressure a -a X 2 a p o 1 ….Eq. 8 3 2h _ a/h Forging pressure Suranaree University of Technology x = -a x=0 x=a September 2007 Example: Dieter, page 574-575 A block of lead 25x25x150 mm3 is pressed between flat dies to a size 6.25x100x150 mm3. If the uniaxial flow stress o = 6.9 MPa and = 0.25, T. Udomphol determine the pressure distribution over the 100 mm dimension (at x = 0, 25 and 50 mm) and the total forging load in the sticky friction condition. 2 y o exp a x 3 h 2 where o' 2 3 o At the centreline of the slab (x = 0) max 2 ( 6 .9 ) 2(0.25) 50 0 435MPa exp 3 6.25 Likewise, at 25 and 50 mm, the stress distribution will be 58.9 and 8.0 MPa respectively. Suranaree University of Technology September 2007 Example: Dieter, page 574-575 The mean forging load (in the sticky friction condition) is _ T. Udomphol p _ p 2 3 a 1 2h o 2(6.9) 50 1 39.8MPa 3 12.5 We calculate the forging load on the assumption that the stress distribution is based on 100 percent sticky friction. Then The forging load is P Suranaree University of Technology = stress x area = (39.8x106)(100x10-3)(150x10-3) = 597 kN = 61 tonnes. September 2007 Defects in forging • Incomplete die filling. T. Udomphol • Die misalignment. files.bnpmedia.com Fluorescence penetrant reveals Forging laps • Forging laps. • Incomplete forging penetration- should forge on the press. • Microstructural differences resulting in pronounced property variation. • Hot shortness, due to high sulphur concentration in steel and nickel. • Residual stresses www.komatsusanki.co.jp See simulation Suranaree University of Technology September 2007 Forging of automobile parts www.jocmachinery.com T. Udomphol www.jocmachinery.com • Metals to be forged • Shape and size • Forging temperature • Strain rate • Forging load • Lubrication Suranaree University of Technology • Die design • Die materials • Die life September 2007 Part II: Sheet metal forming Sheet metal forming T. Udomphol • Permanent deformation by cold forming (RT). • Complex 3D shapes. • The process is carried out in the plane of sheet by tensile forces with high ratio of surface area to thickness. • Friction conditions at the tool-metal interface. • High rate of production and formability Suranaree University of Technology September 2007 Classification of sheetsheet-metal forming (Base on operation) T. Udomphol Classification Blanking Suranaree University of Technology Punching Stretching Stretching Deep drawing September 2007 Classification of sheetsheet-metal forming (Base on operation) T. Udomphol Classification Coining Suranaree University of Technology Stamping Ironing September 2007 Classification of sheetsheet-metal forming (Base on operation) T. Udomphol Classification Folding Bending Suranaree University of Technology Roll forming of sheet Wiping down a flange September 2007 Tooling T. Udomphol Basic tools • Punch A convex tool for making holes by shearing, making surface or displacing metal with a hammer. • Die A concave die (female part). Punches and dies Die materials: Punch and die in stamping Suranaree University of Technology • High alloyed steels heat treated for the punches and dies. September 2007 Compound and transfer dies Compound dies www.lyons.com T. Udomphol • Several operations in one stroke. • Combined processes and create a complex product in one shot. • Stamping processes of thin sheets. Transfer dies www.deltatooling.co.jp/ • Also called compound dies. • The part is moved from station to station within the press for each operation. Suranaree University of Technology September 2007 Introduction to metal forming T. Udomphol Die set consists of 1) Punch holder 2) Die block 3) Pilot 4) Striper plate Schematic diagram of a die set pilot Suranaree University of Technology September 2007 Forming methods T. Udomphol There are a great variety of sheet metal forming methods, mainly using shear and tensile forces in the operation. • Progressive forming • Shearing and blanking • Hydroforming • Bending and contouring • Stretch forming • Spinning process • Explosive forming • Deep drawing • Stamping Suranaree University of Technology September 2007 Progressive forming www.hillengr.com Punch T. Udomphol Stripper plate Die Strip washer Progressive die • Optimise the material usage. • Determining factors are 1) volume of production washers Suranaree University of Technology 2) the complexity of the shape September 2007 Hydroforming • Using Rubber or polyurethane pad as dies. • Single - action hydraulic press. T. Udomphol • Pressure medium- water or oil. • Transmits a nearly uniform hydrostatic pressure against the sheet. • Pressure ~ 10 MPa or higher www.thefabricator.com Hydroforming Suranaree University of Technology September 2007 Stretch forming • Using tensile forces, normally for uniform cross section). T. Udomphol • required materials with appreciable ductility. Ram Ram www.ducommunaero.com Suranaree University of Technology September 2007 Explosive forming T. Udomphol • Explosive charge is detonated in medium (water) at an appropriate standoff distance from the sheet blank at a very high velocity. • The shockwave propagating from the explosion serves as a ‘friction-less punch’ Suranaree University of Technology September 2007 Stamping T. Udomphol • Key factors: data collections on die sets, die failure and material handling damage and machine failure to identify weak areas in the stamping process. www.ugs.com/ www.fpi.co.th • Materials require good ductility, work hardening and strength img.alibaba.com Panel, fender, bumper Automotive stamped parts Suranaree University of Technology Automobile panel die September 2007 Stamping T. Udomphol • Multi-cone design giving structural integrity and rigidity equivalent to a steel beam panel at half the weight, and without cutouts, www.psc.edu Suranaree University of Technology Aluminium inner hood panel September 2007 Shearing and blanking Clearance T. Udomphol • Proper (a) Proper clearance Ragged surface (normally 2-10% thickness) clean fracture surface. • Insufficient ragged fracture surface. • Excessive greater distortion, greater energy required to separate metal. (b) Insufficient clearance blurr Thickness clearance (c) Excessive clearance Suranaree University of Technology September 2007 Bending and contouring www.macri.it T. Udomphol Wiper rolls Form block www.lathes.co.uk Clamp Clamp Tension Suranaree University of Technology September 2007 Bending and contouring • Outer surface strained. • Inner surface contracted. T. Udomphol b/h R thickness on bending Springback Suranaree University of Technology biaxiality Strain, ductility Cracks occur near the centre of the sheet September 2007 Spinning process • Deep parts of circular symmetry such as tank heads, television cones. T. Udomphol Materials: aluminium and alloys, high strength - low alloy steels, copper, brass and alloys, stainless steel, (a) Manual spinning Suranaree University of Technology (b) Shear spinning September 2007 Deep drawing • Shaping flat sheets into cup-shaped articles. Examples: bathtubs, shell cases, automobile panels. T. Udomphol A cup is subjected to three different types of deformation. Lamp cover Stresses and deformation in a section from a drawn cup Suranaree University of Technology September 2007 Deep drawing • Die radius – 10 x sheet thickness. T. Udomphol • Punch radius – Clearance between punch and die ~10-20% > sheet thickness. • Hold-down pressure – ~ 2% of o and u. • Lubrication of die side. • Material properties - low yield stress, high work hardening rates. Suranaree University of Technology Thickness profile of drawn cup Clearance > 10-20% thickness. September 2007 Forming limit criteria T. Udomphol • Stretching of circles into ellipses after punching Major strain 120 • Percentage changes in these strains are compared in the diagram. 100 1(%) Failure 80 60 2 -40 Grid analysis (a) before (b) after deformation of sheet. Suranaree University of Technology -20 B AK steel 2 Safe 40 1 A 1 20 0 20 40 Minor strain 60 2(%) 80 100 Forming limit diagram September 2007 Defects in formed parts T. Udomphol www.bgprecision.com Springback problem ~ 55o for an isotropic material in pure tension Edge condition u 2n Localised necking in a strip in tension Suranaree University of Technology Crack near punch & shoulder September 2007 Introduction to metal forming aluminium.matter.org.uk T. Udomphol Earing in drawn can •Radial crack •Surface blemish (orange peel) •Wrinkling Stretcher strain in low-carbon steel. Suranaree University of Technology •Mechanical fibering September 2007 Processing route T. Udomphol Tool geometry -Die -Punch -Blankholder -Drawbeads -Spacers Material characteristics -Stress-strain curve -Directionality -Forming criteria -Young’s modulus -Friction Process parameters -Process steps -Blank outline -Blankholder pressure -Blankholder stiffness -Stress relief cuts -Sheet gauge -Drawbeads -Friction Forming simulation Forming Result www.thefabricator.com Suranaree University of Technology September 2007 References T. Udomphol • Dieter, G.E., Mechanical metallurgy, SI metric Edition, 1988, McGraw-Hill, ISBN 0-07-100406-8 • Edwards, L. and Endean, M., Manufacturing with material, 1998, Butterworth Heinemann, ISBN 0 7506 2754 9. • Beddoes, J. and Bibbly M.J., Principles of metal manufacturing process, 1999, Arnold, ISBN 0-470-35241-8. • Lange, K., Handbook of metal forming, 1985, R.R Donnelly & Sons Company, ISBN 0-07-036285-8. •Lecture notes, Sheffield University, 2003. •Lecture notes, Birmingham University, 2003. •Lecture notes, Metal forming processes, Prof Manus Satirajinda. Suranaree University of Technology September 2007