Search Results for beading dies

This article discusses the principles of the press-brake forming process and its applicability with an example. It describes the types of press brakes and examines some considerations, which help in the selection of machine. The article provides information on flattening dies, gooseneck punches, wiping dies, channel dies, arbor-type punches, box-forming dies, curling dies, beading dies, and cam-driven dies, with illustrations. It discusses the tool material selection for various operations. The article explains the procedures used for producing different shapes, including simple boxlike parts, panels, flanged parts, architectural columns, fully closed parts, and semicircular parts. It examines the effect of work metal variables on results in press-brake operations. The article also reviews stock tolerances, design, and condition of machines and tools, which help in obtaining good dimensional accuracy.

This article describes the laboratory techniques for direct measurement and quantification of die wear in verifying a proprietary die-wear predictor methodology. This method is based on a theoretical formula that can be used to predict the rate of die wear and the life of a die surface coating, applicable to both mild steel and high-strength steels stampings. The article discusses the behavior of the surface conditions through quantitative measurements and surface analyses conducted throughout the wear tests. The surface conditions include surface roughness, surface morphology, microstructure, interfacial friction, surface temperatures, and wear rate.

Press brakes are a common and versatile type of equipment for bending metal by delivering an accurate vertical force in a confined longitudinal area. This article begins with a discussion on the design, widening methods, and types of materials used in press brakes. It focuses on the two basic drive systems used in operating press brakes, namely, mechanical and hydraulic drive systems. The article also provides an outline on the tooling associated with press-brakes.

This article discusses the advantages and limitations of drop hammer forming and presents the key factors for determining a process plan. It describes the characteristics of hammers and presents information on tool materials. It explains the use of lubricants and preparation of blanks for forming. The article also details the drop hammer forming process of steels, aluminum alloys, magnesium alloys, and titanium alloys.

The measurement techniques for die wear can be classified into the following two categories: direct measurements, which are done using lab techniques; and indirect nondestructive measurements, which are done by plant monitoring. This article describes the details of the plant monitoring techniques, along with comprehensive discussions on the measured wear data based on roughness and hardness of die surfaces. It presents a comparison between the predicted and measured die wear rates.

This article introduces process factors that influence die wear and lubrication for metal forming operations such as bending, spinning, stretching, deep drawing, and ironing. It discusses the effects of part shape, sheet thickness, tolerance requirements, sheet metal, and lubrication on shallow forming dies. The article describes the wear of material for dies to draw round and square cup-shaped metal parts in a press. It also discusses the effect of process conditions on the shallow forming dies.

This article describes grade designations of the various sheet steels used for draw forming. It discusses the specifications associated with most sheet draw forming materials. The article examines the behavior of stress- and strain-based forming limit curve (FLC). It provides a discussion on three separate frictional conditions acting in a draw die. The frictional conditions include the metal passing through a draw bead, the metal clamped in the binder, and the metal sliding across a die radius. The article also explains the basic steps in the vehicle development process. The steps involved in the thought process of direct engineering for formability are also explained. The article places considerable emphasis on the need for the designer to clearly define the die/tooling faces in the computer-aided design (CAD)/computer-aided manufacturing (CAM) system before the data are passed on to the construction functions.

This article reviews the selection and formability characteristics of steels, with an emphasis on low-carbon steels and some coverage on the forming of high-carbon steels. It describes the key factors that affect the formability of steels in terms of steelmaking practices, surface finishes, metal thicknesses, and alloying. The article explains the bending and forming operations with some examples. It also describes the formation of various shells, including doubly contoured shells, deep recessed shells, and deep circular shells.

Control of grain flow is one of the major advantages of shaping metal parts by rolling, forging, or extrusion. This article shows the effects of anisotropy on mechanical properties. Cylindrical forgings commonly have a straight parting line located in a diametral plane. The alternate classes of parting lines are called either "straight" or "broken" for brevity. Regardless of whether draft is applied or natural, the forging will have its maximum spread or girth at the parting line. Proper placement of the parting line ensures that the principal grain flow direction within the forging will be parallel to the principal direction of service loading. The article reviews the mutual dependence of parting line and forging process. It provides a checklist for the forging designer that suggests a systematic approach for establishing parting line location. Finally, the article contains examples, with illustrations of parting line locations, accompanied by tables of design parameters.

This article illustrates the mechanics of the deep drawing of a cylindrical cup. It discusses the fundamentals of drawing and drawability. Sheet metal is drawn in either hydraulic or mechanical presses. The article summarizes the defects in drawing and factors considered in press selection for drawing. It explains the types of dies used for drawing sheet metal and the effects of process variables and material variables on deep drawing. The process variables that affect the success or failure of a deep-drawing operation include the punch and die radii, punch-to-die clearance, press speed, lubrication, and type of restraint of metal flow used. The article describes the process of redrawing and ironing of metals. Drawing of workpieces with flanges and drawing of hemispheres are also illustrated. The article also provides information on the reducing of drawn shells, methods for expanding portions of drawn workpieces, trimming, and deep drawing using fluid-forming presses.

In terms of forming, magnesium alloys are much more workable at elevated temperatures due to their hexagonal crystal structures. This article describes the deformation mechanisms of magnesium and provides information on the hot and cold forming processes of magnesium alloys and the lubricants used in the processes. It discusses the various forming processes of magnesium alloys. These include press-brake forming, deep drawing, manual and power spinning, rubber-pad forming, stretch forming, drop hammer forming, and precision forging.

This article discusses the general formability considerations of aluminum alloys. To conduct a complete analysis of a formed part, the required mechanical properties, as determined by several standard tests, must be considered. The article describes tension testing and other tests designed to simulate various production forming processes, including cup tests and bend tests, which help in determining these properties. It provides information on the equipment and tools, which are used in the forming of aluminum alloys. The article presents a list of lubricants that are most widely used in the forming. It also analyzes the various forming processes of aluminum alloys. The processes include blanking and piercing, bending, press-brake forming, contour roll forming, deep drawing, spinning, stretch forming, rubber-pad forming, warm forming, superplastic forming, explosive forming, electrohydraulic forming, electromagnetic forming, hydraulic forming, shot peening, and drop hammer forming.

Stretch forming is the forming of sheet, bars, and rolled or extruded sections over a die or form block of the required shape while the workpiece is held in tension. This article discusses the applicability, advantages, and machines and accessories of stretch forming. It provides a detailed discussion on four methods of stretch forming, namely, stretch draw forming, stretch wrapping, compression forming, and radial draw forming.

This article briefly reviews the forming of steel tailor-welded blanks (TWB) with a discussion on the effects of welding on forming. It presents the parameters that are monitored to control the stamping operation for tailor-welded blanks. The article discusses weld factors such as the orientation of weld relative to metal movement in dies, the formability of TWB materials, die and press considerations, and specific factors for the drawing, stretching, and bending of steel tailor-welded blanks.

This article describes the methods for removing metallic contaminants, tarnish, and scale resulting from hot-working or heat-treating operations on nickel-, cobalt-, and iron-base heat-resistant alloys. It provides a brief description of applicable finishing and coating processes, including polishing, electroplating, ceramic coatings, diffusion coatings, and shot-peening. The article presents numerous examples that identify cleaning and finishing problems and the procedures used to solve them.

Simulation programs are becoming more effective tools in reducing the need for physical testing and the avoidance of costly downstream problems by solving the problems upfront in the early development stage. This article provides a brief review of the history and applied analysis of simple forming operations. It focuses on metal stamping simulation based on the finite-element methods or model (FEM) with emphasis on software tools using the three-dimensional FEM technology. The article discusses two aspects of particular importance in finite-element analysis of sheet forming and springback analysis: the type of solution algorithm/governing equation and the type of element. The article provides information on various models for material yield criteria.

This article discusses the selection of types of stainless steel for various methods of forming based on the formability and on the power required for forming. It reviews the requirements of lubrication, blanking, and piercing. The article describes various forming methods, namely, press-brake forming, press forming, multiple-slide forming, deep drawing, spinning, rubber-pad forming, drop hammer forming¸ three-roll forming, contour roll forming, stretch forming, and bending of tubing.

This article focuses on the technology breakthroughs that make forming simulation a routine work throughout the industry. It discusses many forms of the computer-aided engineering (CAE) methodology. The article describes several failure criteria to predict the failure of sheet metal. It explains the numerical procedure for sheet metal forming and reviews the important technical issues in CAE simulations. The article provides information on the applications and process of metal-forming simulation. It also reviews the capabilities of major systems that are popular among sheet metal forming users worldwide.