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ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Processes
Shearing Bending Shear Spinning Tube Drawing
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Bending
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Bending analysis
As the punch descends, contact forces at the die produce bending moments near the punch, of large enough magnitude, to produce the required deformation.
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Bending analysis
t rd b = width l rp punch
die
Bending analysis
Assume b >> t, so we have plane strain. First, analyze the strain in the sheet.
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Strain in sheet
rp t 0 0 A A N.A.
etensile
l OA OA = = l OA
9
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Strain in sheet
l = r
rp + t r p + etensile = t rp + 2 t rp + t r p 2 etensile = t rp + 2
t 2
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Strain in sheet
etensile = t 2 t rp + 2
etensile
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Strain in sheet
The neutral axis actually moves about 5% to the compression side.
etensile =
1 rp 0.82 + 1.8 t
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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14
1 rp = t 1 2 RA
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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eelastic
yield
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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t t 2 Mb = 2 yield b 2 2
Mb =
yield bt 2
4
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Elasticplastic material
There is usually some elasticity in the center, otherwise you would exceed the maximum elongation in the metal.
yield E t/2 yield a/2
yield
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ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Elasticplastic material
Moment produced by elastic region
M elastic a 2 a = 2 yield 2 b 2 3 2
M elastic =
yield ba 2
6
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ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Elasticplastic material
Moment produced by plastic region
M plastic = 2 yield a ta ta b + 4 2 2
(2 sides, stress, width, center of action of plastic region, thickness of plastic region)
M plastic =
yield b t 2 a 2
4
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Elasticplastic material
M b = M elastic + M plastic
Mb =
yield ba 2
6
+
2
yield b t 2 a 2
4
2
Mb =
yield b
12
3t a
)
22
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
= yield + ke
1 yield 1
2
yield k e yield
yield
Mb =
yield bt
4
+ M triangle section
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ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
yield
Strain hardening
1
M triangle section
1 t 2 t = 2 1 yield b 2 2 3 2
M triangle section
(1 yield ) bt 2 =
6
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Strain hardening
Mb =
Mb =
yield bt
4
(1 yield ) bt +
6
1 + 2 1 yield
yield bt
12
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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F N
Mb N
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Bending force
M0 = 0
l Mb = N cos
F = 0
F = 2 [N cos + N sin ]
M b cos N= l
]
27
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
dF =0 d
and
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sin 2 = cos 2
sin 2 = = tan 2 cos 2
Maximum force at
1 = tan 1 2
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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max
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Springback
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M Myield EI
1/yield 1/final
1/bent
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
+
yield plastic t/6 yield/2 t/3 yield t/6
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-yield
t/3
yield/2
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
final
bent
elastic
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final bent
bent
elastic 1 = bent
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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= a constant
hence
bent
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elastic
M b 12M b = = EI Ebt 3
Mb =
combining
yield bt 2
4
3 bent yield Et
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bent
12 bent M b Ebt
3
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
bent
t = rp + 2
t 12M b t 3 yield = rp + = rp + 3 2 Ebt 2 Et
punch
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Springback elastic-plastic
Non-strain hardening, not fully plastic, bottoming die Total moment
t2 a 2 M b = yield b 4 12
Elastic region 2 yield 1 = bent Ea
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Springback elastic-plastic
2 2 4 bent yield b 3 yield t 2 Mb = 2 12 E
Unloading which produces an elastic stress moment of the same magnitude, would produce the curvature
elastic
M b 12 M b = = EI Ebt 3
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Springback elastic-plastic
Substituting into Mb
2 4 bent 3 b yield 2 3 yield t 12 E2
b Et 3 = 12 elastic
rearranging
elastic
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Springback elastic-plastic
bent elastic
from above
3 3 yield bent 4 bent 3 yield = 3 3 Et E t
43
Springback elastic-plastic
from above
bent
hence
bent
yield bent = 3 Et
yield bent 4 Et
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Springback elastic-plastic
For a bottoming die (bent = punch)
bent
t = rp + 2
yield t rp + 4 2 Et t rp + 2
3
punch
yield = 3 Et
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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yield bt
12
1 + 2 1 yield
Unloading which produces an elastic stress moment of the same magnitude, would produce the curvature
elastic
M b 12 M b = = EI Ebt 3
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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yield bt
12
1 + 2 1 yield
yield
Et
3 b = Et 12 elastic
rearranging
elastic
2 1 1 + yield
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ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
bent
combining
bent
bent yield
Et
2 1 1 + yield
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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bent
t = rp + 2
punch
t yield = rp + 2 Et
1 + 2 1 yield
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Springback note
If punch does not bottom in die, then springback in the arms needs to be considered. For example, air bending
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Stretch bending
sheet is in tension while being bent fill tubes with sand and stretch to prevent buckling and collapse
Heating
softens material, lowers flow stress, increases ductility
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Bendability
Assess bendability (rp/t) as b (length of bend) increases
ductility of sheet metal decreases
uniaxial to biaxial stress state (plane strain)
minimum rp increases
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Bendability
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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etensile
so the max strain is less than the max elongation also, check to see if we are plastic:
eelastic =
yield
E
56
= yield + ke
solving for k
= 50,000 + 75,320 e
substituting the strain
57
yield bt 2
12
2 1 1 + yield
substituting data
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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]
]
2 35.74 F = cos2 2.86 + 0.1 sin 2.86 cos 2.86 = 71.7 lbf 1
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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punch
punch
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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final
die
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Shear Spinning
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Shearing geometry
t original blank roller t flange c /2 mandrel
after Kalpakcioglu (1961)
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
tc
tc = t sin
tailstock
63
Ideal process
Flange Dt Roller f /2 R=Dc/2 dR /2
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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= cot
cot
2
65
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
cot
u=
d = d
0
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Strain
From distortion energy theory
2 2 2 2 (1 2 ) + ( 2 3 ) + ( 3 1 ) = 3
for plane strain 1 = -3, and 2 =0
1 2
2 2 2 = (1 0) + (0 1 ) + (1 1 ) 3
from Mohrs circle
1 2 2
2 = 1 3
hence
= 3
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ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Strain
Substituting for shear strain,
1 = = cot cot 2 2 3 3
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Power
d (vol ) P =u dt
where
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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d
0
1 = tfDc sin d 2 2
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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2 = 90
yield
1 3 cot
yield
Power =
1 3
2
71
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Torque =
1 2 3
Ftangential =
tf yield cos
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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Tube Drawing
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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t 1 f ti
B*
2 2 B tan
*
2 B tan
*
B*
tan
Moving mandrel with friction towards exit, takes into account motion between mandrel and tube (B may be negative) (plane)
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Summary
Analyses for
Shearing Bending Shear Spinning Tube Drawing
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
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