INTRODUCTION TO SHEET METAL FORMING PROCESSES

Introduction to sheet metal forming processes

INTRODUCTION TO SHEET METAL FORMING PROCESSES

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? 1999 SIMTECH. All rights reserved Product names are mentioned for identification only and may be registered

trademarks.

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Copyright ? 2001 SimTech Simulation et Technologie All rights reserved

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Introduction to sheet metal forming processes

INTRODUCTION: EVOLUTION OF INDUSTRIAL STAMPING

Back in 1985, the development cycle of a stamped part looked more or less like this (a sequential series of operations stemming from a single style design):

STYLE DESIGN

Product Pd

Dt esignPrPocess

Dev.

Product

Devpt.

Soft/Hard tool built

Soft/Hard tool tryout

42 months

Today, people look at it rather as a sort of funnel, where key decisions are taken on the basis of different factors and alternative choices.

style product-processtooling CAM

design validation

tryout

proces

18 months

production

Copyright ? 2001 SimTech Simulation et Technologie All rights reserved

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Introduction to sheet metal forming processes

OVERVIEW: THE STAMPING SYSTEM AND STAMPING DESIGN

Like all complex system, stamping can be decomposed in hardware and software. By hardware we mean factors that cannot be changed from one operation to another. Conversely, by software we mean factors that the operator can change in order to obtained the desired result : a part with a given quality.

HARDWARE

SOFTWARE

Press

Press set-up

Tools

Material

Lubrication

The highlighted areas represent the components of the stamping design.

Copyright ? 2001 SimTech Simulation et Technologie All rights reserved

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Introduction to sheet metal forming processes

What is a stamping press ?

A stamping press is a machine that houses the stamping tools (tooling) and carries them around according to the kinematics indicated by the user (process set-up). The knowledge of the press used for a stamping operation provides us with useful clues regarding:

? Value and distribution of restraining forces ? Tool deformation caused by stamping forces ? Contact and/or gap between tools and blank However, we should recall that, at the moment when the die design is carried out, the press is usually not yet known, so that its characteristics are rather a factor of noise than a useful information. Therefore, it will be important to have a design that is robust with respect to the press type.

Copyright ? 2001 SimTech Simulation et Technologie All rights reserved

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Introduction to sheet metal forming processes

What is a stamping tool? What is process design?

die design area

Run-offs

blankholder

punch

blankholder

GLOSSARY:

Design surface

Part as designed to fit in the car (after trimming)

Blankholder surface

Surfaces that hold the blank before the forming operation, including the restraining

Production surface/run-offs

Junction between the two former surfaces, protecting the design surface and controlling material flow

Dieface

Run-offs + blankholder

Process design is the ensemble of operations leading from the design geometry to the dieface.

Copyright ? 2001 SimTech Simulation et Technologie All rights reserved

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