Heinz Tschaetsch Metal Forming Practise

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1 Heinz Tschaetsch Metal Forming Practise

2 Heinz Tschaetsch Metal Forming Practise Processes Machines Tools Translated by Anne Koth 123

3 Author: Professor Dr.-Ing. e. h. Heinz Tschaetsch Paul-Gerhardt-Str Dresden, Germany and Kaiserplatz 2a Bad Reichenhall, Germany Translator: Anne Koth Allsprach-Übersetzungsbüro Wilthener Str. 6a Dresden, Germany Originally German edition published by Vieweg Verlag, Wiesbaden 2005 Library of Congress Control Number: ISBN Springer Berlin Heidelberg New York ISBN Springer Berlin Heidelberg New York This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer. Violations are liable for prosecution under the German Copyright Law. Springer is a part of Springer Science+Business Media springer.com Springer-Verlag Berlin Heidelberg 2006 Printed in Germany The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Cover design: Erich Kirchner, Heidelberg Production: LE-TEXJelonek,Schmidt&VöcklerGbR,Leipzig Printed on acid-free paper 62/3100/YL

4 Preface The book Metal Forming, a translation of the eighth revised edition of Umformtechnik in German, describes the latest technology in the sector of metal forming. Part I covers metal forming and shearing processes. It describes the main features of these processes, the tooling required and fields of application. Practical examples show how to calculate the forces involved in forming and the strain energy. Part II describes forming machines and shows how to calculate their parameters. This section also introduces flexible manufacturing systems in metal forming and the handling systems required for automation (automatic tool changing and workpiece conveyor systems). Part III includes tables and flow diagrams with figures needed to calculate forming forces and strain energy. These production units are automated as much as possible using modern CNC engineering to reduce non-productive time and changeover time, and thus also manufacturing costs. Alongside these economic advantages, however, another important reason for using metal working processes is their technical advantages, such as: material savings optimal grain direction work hardening with cold forming. This book runs through all the main metal forming and shearing processes and the tooling and machines they involve. Incremental sheet forming was recently added in Chapter For engineers on the shop floor, this book is intended as an easily-navigable reference work. Students can use this book for reference, saving them time making notes in the lecture theatre so that they can pay better attention to the lecture. I would particularly like to thank my colleague, Prof. Jochen Dietrich, Ph.D.eng. h.c., lecturer in production processes and CNC engineering at Dresden University of Applied Sciences, Germany (Hochschule für Technik und Wirtschaft), for his involvement as co-author from the 6 th edition. Thanks also to Dr. Mauerman of the Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany (Institut für Werkzeugmaschinen und Umformtechink), for his collaboration on the 7 th edition of the book. Bad Reichenhall and Dresden, November 2005 Heinz Tschätsch

5 Contents Preface... Terms, symbols and units... 1 Part I Metal forming and shearing processes Types of production processes Terms and parameters of metal forming Plastic (permanent) deformation Flow stress Deformation resistance Deformability Degree of deformation and principal strain Strain rate Exercise Surface treatment Cold bulk forming Cold sheet forming Hot forming Exercise Upset forging Definition Application Starting stock Permissible deformations Upsetting force Upsetting work Upsetting tooling Achievable precision Defects in upset forging Example calculations Exercise Extrusion Definition Application of the process Types of extrusion process Starting stock Principal strain Calculation of force and mechanical work Extrusion tooling Reinforcement calculation for single-reinforced dies Achievable precision Defects during extrusion V

6 VIII Contents 5.11 Sequence of operations diagram Example calculations Shape classification Exercise Thread and gear rolling Types of process Application of the processes Advantages of thread rolling Establishing the initial diameter Rolling speeds with cylindrical dies Rolling dies Example Thread rolling machines Exercise Processes and machines for rolling gears Cold hubbing Definition Application of the process Permissible deformations Calculation of force and mechanical work Materials which can be hubbed Hubbing speed Lubrication during hubbing Characteristics of the workpieces to be hubbed Hubbing tooling Advantages of cold hubbing Defects during cold hubbing Machines for cold hubbing Example calculations Exercise Coining (stamping) Definition Types and applications of coining processes Calculation of force and mechanical work Tooling Defects during coining Example Exercise Ironing (wall ironing) Definition Application of the process Starting stock Principal strain Calculation of force and mechanical work Example Exercise... 94

7 Contents IX 10 Wire drawing Definition Application Starting stock Principal strain Permissible deformations Drawing force Drawing speeds Drive power Drawing tooling Example Exercise Tube drawing Definition Tube drawing processes Principal strain and drawing force Drawing tooling Example Exercise Extrusion Definition Application Starting stock The extrusion process Principal strain Strain rates during extrusion Extrusion force Mechanical work Tooling Extrusion presses Example Exercise Impression-die forging (closed-die forging) Definition Starting stock Types and application of the process Processes in the forging die Calculation of force and mechanical work Tooling Design of impression-die forgings Achievable precision Example Exercise Deep drawing Definition Application of the process

8 X Contents 14.3 Forming process and stress distribution Starting stock Permissible deformation Deep drawing steps Calculating the drawing force Blank holder force Drawing work Drawing tooling Achievable precision Defects during deep drawing Example Hydromechanical deep drawing Sheet hydroforming Tube hydroforming Exercise Deep drawing without a blank holder; metal spinning Deep drawing without a blank holder Metal spinning Exercise Incremental sheet forming Bending Definition Application of the process The bending process Limits of bending deformation Spring-back Determining the blank length Bending force Bending work Bending tooling Bending defects Example Bending machines Exercise Embossing Definition Application of the process Calculation of force and mechanical work Embossing tooling Embossing defects Example Exercise Shearing Definition Shearing process flow Types of shearing process

9 Contents XI 18.4 Permissible deformation Calculation of force and mechanical work Resultant line of action Break clearance Web and rim thickness Achievable precision Shearing tooling Example Exercise Fine blanking (precision blanking) Definition Fields of application Shearing process flow Fine blanking tooling design Break clearance Forces during fine blanking Fine blanking presses Exercise Laser cutters Joining by forming Clinching Punch riveting Self-piercing riveting with semi-tubular rivets Part II Presses 21 Types of press Presses controlled by work Presses controlled by the ram path Presses controlled by force Exercise Hammers Columns and frames Types of hammer Constructional design and calculation of impact energy Fields of application for hammers Example Exercise Screw presses Forms of structural design Functions of the individual styles of construction Calculating the parameters for screw presses Advantages of screw presses Typical fields of application of screw presses Examples Exercise

10 XII Contents 24 Eccentric and crank presses Types of these presses Press frame materials Frame deflection and deflection energy Eccentric and crank press drives Calculating the parameters Example Application of eccentric and crank presses Exercise Knuckle-joint and toggle presses Single-point knuckle-joint presses Toggle presses modified knuckle-joint presses Horizontal knuckle-joint and toggle presses Exercise Hydraulic presses Hydraulic press drives Example Advantages of hydraulic presses Practical application of hydraulic presses Exercise Special-purpose presses Deep drawing transfer presses Transfer presses for bulk forming Automatic punching presses Exercise Workpiece and stock feed systems Feed devices for piercing or blanking operations Transport devices in deep drawing transfer presses Transport devices for transfer presses for bulk forming Feed devices to supply round blanks Feed devices to convey single workpieces in steps Feed devices to supply forging presses Exercise Future developments in metal forming presses and tool changing systems Flexible manufacturing systems Automatic tool change systems Part III Tables Bibliography Index

11 Terms, symbols and units Term Symbol Unit (selection) Work, mechanical W Nm Force (force of pressure) F N Drawing force F dr N Blank holder force F BH N Velocity m/s, m/min Strain rate s 1 Pressure p Pa, bar Shear stress N/mm2 Tensile stress R, N/mm2 Tensile strength R m N/mm 2 Yield strength R e N/mm 2 Elastic limit R P0.2 N/mm 2 Elongation m/m, % Flow stress k str N/mm 2 Flow stress before forming (cold forming) k str 0 N/mm 2 Flow stress after forming (cold forming) k str 1 N/mm 2 Resistance to flow p fl N/mm 2 Deformation resistance k r N/mm 2 Modulus of elasticity E N/mm 2 Density t/m 3, kg/dm 3, g/cm 3 Blank length before forming h 0, l 0 m, mm Blank length after forming h 1, l 1 m, mm Area A m 2, mm 2 Area before forming A 0 m 2, mm 2 Area after forming A 1 m 2, mm 2 Volume V m 3, mm 3 Forming temperature T K, ºC Coefficient of friction Efficiency

12 2 Terms, symbols and units Term Symbol Unit (selection) Deformation efficiency F Impact effect (with hammers) i Power P Nm/s, W Acceleration a, g m/s 2 Press strokes per minute n min 1, s 1 Stroke length H, h m, mm Mass moment of inertia I d, kgm 2 Mass m kg Angular velocity s 1 Moment M Nm, J Tangential force (with crank presses) T p N Crank angle (with crank presses) º

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