Tsch?tsch H., Koth A. Metal Forming Practise: Processes - Machines - Tools
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Heinz Tschaetsch
Metal F orming Practise
Heinz Tschaetsch
Metal Forming
Practise
Processes – Machines – Tools
Translated by Anne Koth
123
Author:
Professor Dr.-Ing. e. h. Heinz Tschaetsch
Paul-Gerhardt-Str. 25
01309 Dresden, Germany
and
Kaiserplatz 2a
83435 Bad Reichenhall, Germany
Translator:
Anne Koth
Allsprach-Übersetzungsbüro
Wilthener Str. 6a
01324 Dresden, Germany
Originally German edition published by Vieweg Verlag, Wiesbaden 2005
Library of Congress Control Number: 2006926219
ISBN-10 3-540-33216-2 Springer Berlin Heidelberg New York
ISBN-13 978-3-540-33216-9 Springer Berlin Heidelberg New York
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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 cal-
culate 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. Along-
side 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 15.4.
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
Contents
Preface ................................................................................................................................ V
Terms, symbols and units ................................................................................................. 1
Part I Metal forming and shearing processes ................................................................. 3
1 Types of production processes .............................................................................. 5
2 Terms and parameters of metal forming ............................................................. 7
2.1 Plastic (permanent) deformation ............................................................................... 7
2.2 Flow stress ................................................................................................................
8
2.3 Deformation resistance.............................................................................................. 10
2.4 Deformability............................................................................................................ 11
2.5 Degree of deformation and principal strain .............................................................. 11
2.6 Strain rate.................................................................................................................. 14
2.7 Exercise..................................................................................................................... 14
3 Surface treatment ................................................................................................... 15
3.1 Cold bulk forming..................................................................................................... 15
3.2 Cold sheet forming.................................................................................................... 16
3.3 Hot forming............................................................................................................... 17
3.4 Exercise..................................................................................................................... 17
4 Upset forging .......................................................................................................... 18
4.1 Definition .................................................................................................................. 18
4.2 Application................................................................................................................ 18
4.3 Starting stock ............................................................................................................ 18
4.4 Permissible deformations.......................................................................................... 19
4.5 Upsetting force.......................................................................................................... 23
4.6 Upsetting work.......................................................................................................... 23
4.7 Upsetting tooling....................................................................................................... 24
4.8 Achievable precision................................................................................................. 26
4.9 Defects in upset forging ............................................................................................ 27
4.10 Example calculations ................................................................................................ 27
4.11 Exercise..................................................................................................................... 32
5 Extrusion ................................................................................................................. 33
5.1 Definition .................................................................................................................. 33
5.2 Application of the process......................................................................................... 33
5.3 Types of extrusion process........................................................................................ 34
5.4 Starting stock ............................................................................................................ 35
5.5 Principal strain .......................................................................................................... 35
5.6 Calculation of force and mechanical work................................................................ 36
5.7 Extrusion tooling....................................................................................................... 38
5.8 Reinforcement calculation for single-reinforced dies.................................................... 39
5.9 Achievable precision ................................................................................................ 42
5.10 Defects during extrusion .......................................................................................... 43
VIII Contents
5.11 Sequence of operations diagram .............................................................................. 43
5.12 Example calculations ................................................................................................ 44
5.13 Shape classification .................................................................................................. 49
5.14 Exercise..................................................................................................................... 55
6 Thread and gear rolling ......................................................................................... 56
6.1 Types of process ....................................................................................................... 56
6.2 Application of the processes .................................................................................... 58
6.3 Advantages of thread rolling .................................................................................... 59
6.4 Establishing the initial diameter ............................................................................... 60
6.5 Rolling speeds with cylindrical dies ......................................................................... 61
6.6 Rolling dies .............................................................................................................. 61
6.7 Example..................................................................................................................... 63
6.8 Thread rolling machines ........................................................................................... 64
6.9 Exercise..................................................................................................................... 68
6.10 Processes and machines for rolling gears ................................................................. 69
7 Cold hubbing .......................................................................................................... 77
7.1 Definition ................................................................................................................. 77
7.2 Application of the process ........................................................................................ 77
7.3 Permissible deformations ......................................................................................... 78
7.4 Calculation of force and mechanical work ............................................................... 78
7.5 Materials which can be hubbed ................................................................................ 79
7.6 Hubbing speed .......................................................................................................... 80
7.7 Lubrication during hubbing ...................................................................................... 80
7.8 Characteristics of the workpieces to be hubbed ....................................................... 80
7.9 Hubbing tooling ....................................................................................................... 81
7.10 Advantages of cold hubbing ..................................................................................... 82
7.11 Defects during cold hubbing .................................................................................... 83
7.12 Machines for cold hubbing ....................................................................................... 83
7.13 Example calculations ................................................................................................ 84
7.14 Exercise..................................................................................................................... 85
8 Coining (stamping) ................................................................................................. 86
8.1 Definition ................................................................................................................. 86
8.2 Types and applications of coining processes ........................................................... 86
8.3 Calculation of force and mechanical work ............................................................... 87
8.4 Tooling ..................................................................................................................... 88
8.5 Defects during coining ............................................................................................. 89
8.6 Example .................................................................................................................... 89
8.7 Exercise .................................................................................................................... 90
9 Ironing (wall ironing) ............................................................................................. 91
9.1 Definition ................................................................................................................. 91
9.2 Application of the process ........................................................................................ 91
9.3 Starting stock ............................................................................................................ 91
9.4 Principal strain ......................................................................................................... 91
9.5 Calculation of force and mechanical work ............................................................... 93
9.6 Example .................................................................................................................... 93
9.7 Exercise..................................................................................................................... 94
Contents IX
10 Wire drawing .......................................................................................................... 95
10.1 Definition ................................................................................................................. 95
10.2 Application ............................................................................................................... 95
10.3 Starting stock ........................................................................................................... 96
10.4 Principal strain ......................................................................................................... 96
10.5 Permissible deformations ......................................................................................... 96
10.6 Drawing force .......................................................................................................... 97
10.7 Drawing speeds ........................................................................................................ 97
10.8 Drive power ............................................................................................................. 99
10.9 Drawing tooling ....................................................................................................... 100
10.10 Example ................................................................................................................... 102
10.11 Exercise..................................................................................................................... 104
11 Tube drawing .......................................................................................................... 105
11.1 Definition ................................................................................................................. 105
11.2 Tube drawing processes ........................................................................................... 105
11.3 Principal strain and drawing force ........................................................................... 106
11.4 Drawing tooling ....................................................................................................... 107
11.5 Example ................................................................................................................... 108
11.6 Exercise..................................................................................................................... 108
12 Extrusion ................................................................................................................. 109
12.1 Definition ................................................................................................................. 109
12.2 Application ............................................................................................................... 109
12.3 Starting stock ........................................................................................................... 110
12.4 The extrusion process ............................................................................................... 110
12.5 Principal strain ......................................................................................................... 113
12.6 Strain rates during extrusion .................................................................................... 113
12.7 Extrusion force ......................................................................................................... 114
12.8 Mechanical work ...................................................................................................... 116
12.9 Tooling ..................................................................................................................... 118
12.10 Extrusion presses ..................................................................................................... 120
12.11 Example ................................................................................................................... 121
12.12 Exercise..................................................................................................................... 122
13 Impression-die forging (closed-die forging) ......................................................... 123
13.1 Definition ................................................................................................................. 123
13.2 Starting stock ........................................................................................................... 123
13.3 Types and application of the process ....................................................................... 124
13.4 Processes in the forging die ..................................................................................... 126
13.5 Calculation of force and mechanical work ............................................................... 127
13.6 Tooling ..................................................................................................................... 132
13.7 Design of impression-die forgings ........................................................................... 136
13.8 Achievable precision ................................................................................................ 137
13.9 Example ................................................................................................................... 137
13.10 Exercise..................................................................................................................... 139
14 Deep drawing .......................................................................................................... 141
14.1 Definition ................................................................................................................. 141
14.2 Application of the process ........................................................................................ 141
X Contents
14.3 Forming process and stress distribution ................................................................... 142
14.4 Starting stock ............................................................................................................ 143
14.5 Permissible deformation ........................................................................................... 150
14.6 Deep drawing steps .................................................................................................. 152
14.7 Calculating the drawing force .................................................................................. 154
14.8 Blank holder force .................................................................................................... 155
14.9 Drawing work .......................................................................................................... 156
14.10 Drawing tooling ....................................................................................................... 158
14.11 Achievable precision ................................................................................................ 166
14.12 Defects during deep drawing ................................................................................... 167
14.13 Example .................................................................................................................... 169
14.14 Hydromechanical deep drawing ............................................................................... 172
14.15 Sheet hydroforming .................................................................................................. 174
14.16 Tube hydroforming .................................................................................................. 179
14.17 Exercise..................................................................................................................... 184
15 Deep drawing without a blank holder; metal spinning ....................................... 185
15.1 Deep drawing without a blank holder ...................................................................... 185
15.2 Metal spinning .......................................................................................................... 186
15.3 Exercise..................................................................................................................... 192
15.4 Incremental sheet forming ........................................................................................ 193
16 Bending ................................................................................................................... 194
16.1 Definition ................................................................................................................. 194
16.2 Application of the process ........................................................................................ 194
16.3 The bending process ................................................................................................. 194
16.4 Limits of bending deformation ................................................................................. 195
16.5 Spring-back .............................................................................................................. 197
16.6 Determining the blank length ................................................................................... 198
16.7 Bending force ........................................................................................................... 199
16.8 Bending work ........................................................................................................... 201
16.9 Bending tooling ........................................................................................................ 203
16.10 Bending defects ........................................................................................................ 204
16.11 Example .................................................................................................................... 204
16.12 Bending machines .................................................................................................... 205
16.13 Exercise..................................................................................................................... 211
17 Embossing ............................................................................................................... 212
17.1 Definition ................................................................................................................. 212
17.2 Application of the process ........................................................................................ 212
17.3 Calculation of force and mechanical work ............................................................... 213
17.4 Embossing tooling .................................................................................................... 216
17.5 Embossing defects .................................................................................................... 217
17.6 Example .................................................................................................................... 217
17.7 Exercise..................................................................................................................... 217
18 Shearing .................................................................................................................. 218
18.1 Definition ................................................................................................................. 218
18.2 Shearing process flow .............................................................................................. 218
18.3 Types of shearing process ........................................................................................ 219
Contents XI
18.4 Permissible deformation ........................................................................................... 220
18.5 Calculation of force and mechanical work ............................................................... 220
18.6 Resultant line of action ............................................................................................ 222
18.7 Break clearance ........................................................................................................ 225
18.8 Web and rim thickness ............................................................................................. 227
18.9 Achievable precision ................................................................................................ 228
18.10 Shearing tooling ....................................................................................................... 229
18.11 Example ................................................................................................................... 238
18.12 Exercise..................................................................................................................... 240
19 Fine blanking (precision blanking) ....................................................................... 241
19.1 Definition ................................................................................................................. 241
19.2 Fields of application ................................................................................................. 241
19.3 Shearing process flow .............................................................................................. 241
19.4 Fine blanking tooling design .................................................................................... 242
19.5 Break clearance ........................................................................................................ 242
19.6 Forces during fine blanking ..................................................................................... 243
19.7 Fine blanking presses ............................................................................................... 244
19.8 Exercise..................................................................................................................... 246
19.9 Laser cutters ............................................................................................................. 247
20 Joining by forming ................................................................................................. 249
20.1 Clinching .................................................................................................................. 250
20.2 Punch riveting .......................................................................................................... 254
20.3 Self-piercing riveting with semi-tubular rivets ........................................................ 257
Part II Presses
21 Types of press ......................................................................................................... 262
21.1 Presses controlled by work ...................................................................................... 262
21.2 Presses controlled by the ram path ........................................................................... 262
21.3 Presses controlled by force ...................................................................................... 263
21.4 Exercise..................................................................................................................... 263
22 Hammers ................................................................................................................. 264
22.1 Columns and frames ................................................................................................. 264
22.2 Types of hammer ..................................................................................................... 264
22.3 Constructional design and calculation of impact energy .......................................... 266
22.4 Fields of application for hammers ............................................................................ 273
22.5 Example ................................................................................................................... 274
22.6 Exercise..................................................................................................................... 274
23 Screw presses .......................................................................................................... 275
23.1 Forms of structural design ........................................................................................ 275
23.2 Functions of the individual styles of construction ................................................... 276
23.3 Calculating the parameters for screw presses .......................................................... 287
23.4 Advantages of screw presses ............................................................................................ 291
23.5 Typical fields of application of screw presses ......................................................... 291
23.6 Examples .................................................................................................................. 292
23.7 Exercise..................................................................................................................... 294
XII Contents
24 Eccentric and crank presses .................................................................................. 295
24.1 Types of these presses .............................................................................................. 295
24.2 Press frame materials ............................................................................................... 298
24.3 Frame deflection and deflection energy ................................................................... 299
24.4 Eccentric and crank press drives .............................................................................. 300
24.5 Calculating the parameters ....................................................................................... 306
24.6 Example .................................................................................................................... 310
24.7 Application of eccentric and crank presses .............................................................. 312
24.8 Exercise..................................................................................................................... 312
25 Knuckle-joint and toggle presses .......................................................................... 313
25.1 Single-point knuckle-joint presses ........................................................................... 313
25.2 Toggle presses – modified knuckle-joint presses ..................................................... 314
25.3 Horizontal knuckle-joint and toggle presses ............................................................ 317
25.4 Exercise..................................................................................................................... 317
26 Hydraulic presses ................................................................................................... 318
26.1 Hydraulic press drives .............................................................................................. 318
26.2 Example..................................................................................................................... 320
26.3 Advantages of hydraulic presses .............................................................................. 321
26.4 Practical application of hydraulic presses ................................................................ 321
26.5 Exercise..................................................................................................................... 324
27 Special-purpose presses ......................................................................................... 325
27.1 Deep drawing transfer presses ................................................................................. 325
27.2 Transfer presses for bulk forming ............................................................................ 331
27.3 Automatic punching presses ..................................................................................... 339
27.4 Exercise..................................................................................................................... 344
28 Workpiece and stock feed systems ........................................................................ 345
28.1 Feed devices for piercing or blanking operations .................................................... 345
28.2 Transport devices in deep drawing transfer presses ................................................. 346
28.3 Transport devices for transfer presses for bulk forming .......................................... 347
28.4 Feed devices to supply round blanks ........................................................................ 348
28.5 Feed devices to convey single workpieces in steps .................................................. 348
28.6 Feed devices to supply forging presses .................................................................... 349
28.7 Exercise..................................................................................................................... 349
29 Future developments in metal forming presses and tool changing systems ...... 351
29.1 Flexible manufacturing systems ............................................................................... 351
29.2 Automatic tool change systems ................................................................................ 362
Part III Tables ................................................................................................................... 367
Bibliography ....................................................................................................................... 401
Index ......................................................................................................................
............. 403