This lecture describes the special requirements for the successful fabrication of automotive aluminium sheet metal parts with respect to material properties, machinery and drawing equipment and tools. Background in production engineering, some knowledge of sheet metal forming principles and familiarity with the subject matter covered in TALAT This lectures 3701- 3704 is assumed.
TALAT Lecture 2704: Member with Requirement to Fire ResistanceCORE-Materials
This lecture gives an example calculation of the fire resistance of a thermally insulated aluminium I-beam loaded in bending on the basis of a simplified calculation method and of a computer analysis. Basic knowledge of structural engineering is assumed.
This lecture provides a view of types of joints in aluminium structures and how to design and calculate frequently used joints. Basic structural mechanics and knowledge of design philosophy, structural aluminium alloys and product forms is assumed.
TALAT Lecture 4601: Introduction to Brazing of Aluminium AlloysCORE-Materials
This lecture describes the characteristics of brazing aluminium and the process involved; it helps to understand the use potential and the limitations of brazing aluminium. Basic knowledge of aluminium alloys designation system, surface treatment and corrosion behaviour is assumed.
Elyon Industry Co. Ltd supplies various metal products including stainless steel coil and sheet. Their mission is to deliver products with proactive, prompt, and precise service. They aim to provide speedy delivery, consistent quality, and competitive prices driven by their values of purpose and passion. The document then describes their line of efficient stainless steel products and manufacturing process.
The document discusses the ferrous scrap market. It defines ferrous scrap as steel that can be recycled, and describes its sources such as construction demolition and ship breaking. Scrap affects the costs of steel mills, especially electric arc furnaces that can use 80-100% scrap. It also impacts finished steel product prices like rebar and merchant bars. The price of imported Turkish scrap specifically influences markets in Europe.
A project report on working capital management patel shanti steels pvt ltd, ...Babasab Patil
This document provides an overview of Patel Shanti Steels Pvt Ltd, a steel manufacturing company located in Raichur, Karnataka, India. It discusses the company's history, facilities, product portfolio, manufacturing processes, and quality standards. The company produces TMT steel bars using advanced thermo-mechanical treatment processes. It has an annual production capacity of 4,500 metric tons and sells its products across Karnataka through a network of over 150 distributors and dealers. The document provides details on the company's manufacturing techniques and the specifications of its TMT bars to meet the Bureau of Indian Standards.
Indo Aerospace Solutions Private Limited is a leading provider of distribution and supply chain management services for the aerospace and other industries. Headquartered in New Delhi, India, it has a warehouse located in Noida that is 20 minutes from Delhi. In addition to regular parts supply, Indo Aerospace has worldwide links that enable it to source parts from numerous manufacturers and reduce waiting times for customers.
This document discusses cutting tool materials and their properties. It covers various tool materials including carbon steels, high-speed steel, cemented carbides, ceramics, and diamond. Cemented carbides are the most commonly used and contain tungsten carbide and a cobalt binder. The document provides details on selecting cutting tool materials based on the application, and guidelines for cutting tool design including tool angles and operating conditions.
TALAT Lecture 2704: Member with Requirement to Fire ResistanceCORE-Materials
This lecture gives an example calculation of the fire resistance of a thermally insulated aluminium I-beam loaded in bending on the basis of a simplified calculation method and of a computer analysis. Basic knowledge of structural engineering is assumed.
This lecture provides a view of types of joints in aluminium structures and how to design and calculate frequently used joints. Basic structural mechanics and knowledge of design philosophy, structural aluminium alloys and product forms is assumed.
TALAT Lecture 4601: Introduction to Brazing of Aluminium AlloysCORE-Materials
This lecture describes the characteristics of brazing aluminium and the process involved; it helps to understand the use potential and the limitations of brazing aluminium. Basic knowledge of aluminium alloys designation system, surface treatment and corrosion behaviour is assumed.
Elyon Industry Co. Ltd supplies various metal products including stainless steel coil and sheet. Their mission is to deliver products with proactive, prompt, and precise service. They aim to provide speedy delivery, consistent quality, and competitive prices driven by their values of purpose and passion. The document then describes their line of efficient stainless steel products and manufacturing process.
The document discusses the ferrous scrap market. It defines ferrous scrap as steel that can be recycled, and describes its sources such as construction demolition and ship breaking. Scrap affects the costs of steel mills, especially electric arc furnaces that can use 80-100% scrap. It also impacts finished steel product prices like rebar and merchant bars. The price of imported Turkish scrap specifically influences markets in Europe.
A project report on working capital management patel shanti steels pvt ltd, ...Babasab Patil
This document provides an overview of Patel Shanti Steels Pvt Ltd, a steel manufacturing company located in Raichur, Karnataka, India. It discusses the company's history, facilities, product portfolio, manufacturing processes, and quality standards. The company produces TMT steel bars using advanced thermo-mechanical treatment processes. It has an annual production capacity of 4,500 metric tons and sells its products across Karnataka through a network of over 150 distributors and dealers. The document provides details on the company's manufacturing techniques and the specifications of its TMT bars to meet the Bureau of Indian Standards.
Indo Aerospace Solutions Private Limited is a leading provider of distribution and supply chain management services for the aerospace and other industries. Headquartered in New Delhi, India, it has a warehouse located in Noida that is 20 minutes from Delhi. In addition to regular parts supply, Indo Aerospace has worldwide links that enable it to source parts from numerous manufacturers and reduce waiting times for customers.
This document discusses cutting tool materials and their properties. It covers various tool materials including carbon steels, high-speed steel, cemented carbides, ceramics, and diamond. Cemented carbides are the most commonly used and contain tungsten carbide and a cobalt binder. The document provides details on selecting cutting tool materials based on the application, and guidelines for cutting tool design including tool angles and operating conditions.
The document discusses ferrous scrap markets. It defines ferrous scrap as steel that can be recycled, including prime scrap from manufacturing and obsolete scrap from discarded structures. Scrap is a important raw material for electric arc furnaces, comprising up to 100% of their feedstock. Turkey is the world's largest importer of scrap and its scrap price serves as an important regional marker. Global scrap trade is over 120 million tonnes annually and is expected to tighten further as more countries expand electric arc furnace production. Volatility in scrap prices poses challenges for steel producers and consumers.
The document discusses how Commercial Metals Company (CMC) is different from other steel companies. It notes that CMC focuses on long steel products, has diversified its business across five segments including steel mills, fabrication plants, recycling, and marketing/distribution, and has a track record of consistent profitability and financial strength over 26 years. The document aims to show shareholders that CMC's business strategy and performance set it apart from other steel industry firms.
The document discusses friction and heat generation during machining processes. It states that friction between the chip and tool face generates heat, which controls tool wear rate, cutting speed, and material removal rate. There are three zones of heat formation: the shear zone, tool-chip interface, and tool-work interface. It also discusses tool life models, properties required for cutting tool materials, common coating materials used, and factors that influence the selection of cutting parameters and tools for different materials.
This document discusses cutting tool technology. It begins by introducing tool terminology and reasons for tool wear, including failure modes. It then covers cutting parameters and Taylor's tool life equation. An example is provided to calculate tool life for different materials. Finally, the document reviews modern tool materials and technologies, including high-speed machining characteristics.
This document discusses different materials and techniques used in cutting tool manufacturing. It covers common materials like high-speed steel and hardmetals like tungsten carbide, as well as advanced materials like ceramics, diamond, and cubic boron nitride. Coatings are also discussed which provide benefits like hardness, thermal protection and improved performance. New machining techniques covered include high-feed milling, plunge milling, spinning tools and trochoidal milling which aim to reduce vibrations. The document concludes by discussing future areas like micro milling and machining of new materials.
IRJET- Friction Stir Welding of Aluminium AlloysIRJET Journal
The document discusses friction stir welding (FSW) as a process for joining aluminum alloys without melting. It describes how FSW works, the experimental setup used to weld different aluminum alloys, and results showing the welded alloys had improved mechanical properties like hardness and tensile strength compared to the original materials or traditional welding techniques. The conclusion is that FSW is an effective and environmentally friendly way to join difficult-to-weld materials like aluminum alloys.
This lecture reviews briefly the commercially available superplastic aluminium alloys and gives their processing and service properties. General background in production engineering and material science is assumed.
The document provides instructions for performing arc welding of parallel long beads on a mild steel flat bar. It outlines the learning outcomes, objectives, required apparatus and materials which include an arc welding equipment, electrodes, and a mild steel flat bar. Safety guidelines and introduction to arc welding theory are also presented. The procedures describe how to prepare the workpiece and equipment, strike the arc, and make multiple welding passes. Discussion questions address safety precautions and welding techniques.
Effect of Modified AA5356 Filler on Corrosion Behavior of AA6061 Alloy GTA WeldsIJMER
1) The document examines the effect of modified AA5356 filler and grain refiners on the corrosion behavior of AA6061 alloy gas tungsten arc welds.
2) Dynamic polarization testing showed that welds made with 0.5% scandium-modified AA5356 filler using pulsed current welding had the highest pitting corrosion resistance.
3) Optical microscopy revealed that additions of grain refiners like scandium, zirconium, and tibor to the AA5356 filler reduced pit size and density in the fusion zone, improving corrosion resistance compared to unmodified AA5356 filler.
Chronological developments in Cutting Tool MaterialsBilal Syed
This is ap resentation showing the developments of cutting tools materials used from early life to present. their materials, properties, advantages, etc.
This document discusses various manufacturing processes and techniques. It begins by outlining metal cutting theory and traditional machining processes like turning, drilling, and milling. It then covers non-traditional processes such as ultrasonic machining and electrochemical machining. Further sections discuss welding and casting techniques, tolerances and fits, and metal forming processes like rolling, forging, drawing, and hydroforming. The document provides examples, equations, and multiple choice questions related to these manufacturing topics.
PAPER ON WELDABILITY OF H30 ALUMINIUM WITH BS970 MILD STEEL USING FRICTION WE...Journal For Research
Friction welding method is one of the most simple, economical and highly productive method in joining dissimilar materials. It is widely used in the automotive, medical and aerospace industrial applications. The purpose of this present work was to assess the development of solid state juncture of dissimilar materials of H30 aluminum and BS970 mild steel. The joints were obtained by Friction Welding (FW) process, which combines the heat generated from friction between two surfaces. The results were analyzed by means of tensile, Rockwell hardness test and metallographic tests. Solid state welding processes are characterized by the absence of melting and the formation of narrow heat affected zone (HAZ). The metallurgical properties are usually excellent and most of the processes can be mechanized or automated to be used as high production rate processes. The FW proves to be a great method for obtaining junctures between dissimilar materials which is not possible by fusion welding process.
This document provides a list of welding consumables for various welding processes and materials. It includes 108 products grouped by:
- Mild steel and 490MPa high tensile steel (22 products)
- Flux-cored arc welding (3 products for mild steel)
Each product listing includes the trade designation, ASME/AWS classification, JIS standard, filler metal number, and applicable page number for more details. A clickable index is provided for navigating to product pages.
Analysis of Surface cracks in CHQ gradesPiyush Verma
The analysis of Boron CHQ grade coils produced between January and April showed:
1. The 15B25 grade had the highest rejection rates, with over 60% of coils rejected in some heats.
2. Coils of diameter 5.5mm-10mm saw the most rejections, particularly for the 10B21 and 15B25 grades.
3. Some heats like 72754 and 73338 for the 15B25 grade had over 50% of coils rejected, indicating inconsistencies in the production process for these heats.
This document provides instructions for performing oxy-acetylene welding. It outlines the necessary equipment including an oxy-acetylene welding rig, goggles, pliers, and wire brush. The materials are listed as mild steel plates. Safety procedures are described such as wearing protective equipment and knowing the location of emergency equipment. The document then explains the oxy-acetylene welding process and provides step-by-step instructions for welding two steel plates together, including igniting the torch and controlling the molten weld pool. Assessment criteria for evaluating the quality of the welds are also presented.
409 is a titanium stabilised ferritic stainless steel. It forms a light protective rust layer in exhaust gas atmospheres and is readily weldable. Bhavya Steel is one the known suppliers and stockiest of stainless steel 409 sheets plates and coils.in Mumbai with various grades and specifications
TALAT Lecture 4107: General Summary and Future TrendsCORE-Materials
This lecture points out the need of data sources for designing mechanical joints; it describes concepts for FEM-Modelling of mechanical joints. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lectures 4101- 4106 is assumed.
TALAT Lecture 2711: Design of a Helicopter DeckCORE-Materials
This document provides a 3-page summary of the design of an aluminum alloy helicopter deck, including:
1) An overview of the main structural parts, loads, and material properties considered in the design.
2) An analysis of the deck extrusion profile using finite element modeling to check deflections and stresses. The original profile is modified to improve its performance.
3) An analysis of the welded I-beam support structure to check its capacity to resist bending moments from landing loads. Different beam depth options are considered.
4) A brief discussion of a bolted connection design for the support structure.
The document includes calculations to check that structural components satisfy strength and serviceability limit states according
SHEET METAL PART QUALITY IMPROVEMENT THROUGH DIE OPTIMIZATION USING AUTOFORMFarhad ZHalehfar
This document discusses using AutoForm to optimize sheet metal part quality through die optimization. It aims to improve simulation accuracy, standardize simulations, and transition die quality improvement to earlier design stages. This helps decrease part development time and costs. The document outlines past issues, optimization methodology, effective simulation parameters, verification of simulation results against experiments, and examples of optimized sample parts showing quality improvements and successful high production rates after die surface optimization based on simulations.
Tipo Global Corp is a sheet metal manufacturing company that offers OEM/ODM design and tooling, manufacturing, inspection, and logistic services. They have 30 years of experience in high-mix, low-volume production of sheet metal components for electronic machinery, cases, frames, and T5 luminaires. Their equipment includes punch presses, laser cutters, automatic welders, and presses. They produce parts from steel, iron, and aluminum sourced from top Taiwanese suppliers.
This lecture helps to understand how the properties of forgings evolve during the manufacturing process. General understanding of metallurgy and deformation processes is assumed.
This lecture provides a background on aluminium alloys suitable for impact extrusion. It draws attention to raw material parameters which may affect the properties of impact extruded parts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
The document discusses ferrous scrap markets. It defines ferrous scrap as steel that can be recycled, including prime scrap from manufacturing and obsolete scrap from discarded structures. Scrap is a important raw material for electric arc furnaces, comprising up to 100% of their feedstock. Turkey is the world's largest importer of scrap and its scrap price serves as an important regional marker. Global scrap trade is over 120 million tonnes annually and is expected to tighten further as more countries expand electric arc furnace production. Volatility in scrap prices poses challenges for steel producers and consumers.
The document discusses how Commercial Metals Company (CMC) is different from other steel companies. It notes that CMC focuses on long steel products, has diversified its business across five segments including steel mills, fabrication plants, recycling, and marketing/distribution, and has a track record of consistent profitability and financial strength over 26 years. The document aims to show shareholders that CMC's business strategy and performance set it apart from other steel industry firms.
The document discusses friction and heat generation during machining processes. It states that friction between the chip and tool face generates heat, which controls tool wear rate, cutting speed, and material removal rate. There are three zones of heat formation: the shear zone, tool-chip interface, and tool-work interface. It also discusses tool life models, properties required for cutting tool materials, common coating materials used, and factors that influence the selection of cutting parameters and tools for different materials.
This document discusses cutting tool technology. It begins by introducing tool terminology and reasons for tool wear, including failure modes. It then covers cutting parameters and Taylor's tool life equation. An example is provided to calculate tool life for different materials. Finally, the document reviews modern tool materials and technologies, including high-speed machining characteristics.
This document discusses different materials and techniques used in cutting tool manufacturing. It covers common materials like high-speed steel and hardmetals like tungsten carbide, as well as advanced materials like ceramics, diamond, and cubic boron nitride. Coatings are also discussed which provide benefits like hardness, thermal protection and improved performance. New machining techniques covered include high-feed milling, plunge milling, spinning tools and trochoidal milling which aim to reduce vibrations. The document concludes by discussing future areas like micro milling and machining of new materials.
IRJET- Friction Stir Welding of Aluminium AlloysIRJET Journal
The document discusses friction stir welding (FSW) as a process for joining aluminum alloys without melting. It describes how FSW works, the experimental setup used to weld different aluminum alloys, and results showing the welded alloys had improved mechanical properties like hardness and tensile strength compared to the original materials or traditional welding techniques. The conclusion is that FSW is an effective and environmentally friendly way to join difficult-to-weld materials like aluminum alloys.
This lecture reviews briefly the commercially available superplastic aluminium alloys and gives their processing and service properties. General background in production engineering and material science is assumed.
The document provides instructions for performing arc welding of parallel long beads on a mild steel flat bar. It outlines the learning outcomes, objectives, required apparatus and materials which include an arc welding equipment, electrodes, and a mild steel flat bar. Safety guidelines and introduction to arc welding theory are also presented. The procedures describe how to prepare the workpiece and equipment, strike the arc, and make multiple welding passes. Discussion questions address safety precautions and welding techniques.
Effect of Modified AA5356 Filler on Corrosion Behavior of AA6061 Alloy GTA WeldsIJMER
1) The document examines the effect of modified AA5356 filler and grain refiners on the corrosion behavior of AA6061 alloy gas tungsten arc welds.
2) Dynamic polarization testing showed that welds made with 0.5% scandium-modified AA5356 filler using pulsed current welding had the highest pitting corrosion resistance.
3) Optical microscopy revealed that additions of grain refiners like scandium, zirconium, and tibor to the AA5356 filler reduced pit size and density in the fusion zone, improving corrosion resistance compared to unmodified AA5356 filler.
Chronological developments in Cutting Tool MaterialsBilal Syed
This is ap resentation showing the developments of cutting tools materials used from early life to present. their materials, properties, advantages, etc.
This document discusses various manufacturing processes and techniques. It begins by outlining metal cutting theory and traditional machining processes like turning, drilling, and milling. It then covers non-traditional processes such as ultrasonic machining and electrochemical machining. Further sections discuss welding and casting techniques, tolerances and fits, and metal forming processes like rolling, forging, drawing, and hydroforming. The document provides examples, equations, and multiple choice questions related to these manufacturing topics.
PAPER ON WELDABILITY OF H30 ALUMINIUM WITH BS970 MILD STEEL USING FRICTION WE...Journal For Research
Friction welding method is one of the most simple, economical and highly productive method in joining dissimilar materials. It is widely used in the automotive, medical and aerospace industrial applications. The purpose of this present work was to assess the development of solid state juncture of dissimilar materials of H30 aluminum and BS970 mild steel. The joints were obtained by Friction Welding (FW) process, which combines the heat generated from friction between two surfaces. The results were analyzed by means of tensile, Rockwell hardness test and metallographic tests. Solid state welding processes are characterized by the absence of melting and the formation of narrow heat affected zone (HAZ). The metallurgical properties are usually excellent and most of the processes can be mechanized or automated to be used as high production rate processes. The FW proves to be a great method for obtaining junctures between dissimilar materials which is not possible by fusion welding process.
This document provides a list of welding consumables for various welding processes and materials. It includes 108 products grouped by:
- Mild steel and 490MPa high tensile steel (22 products)
- Flux-cored arc welding (3 products for mild steel)
Each product listing includes the trade designation, ASME/AWS classification, JIS standard, filler metal number, and applicable page number for more details. A clickable index is provided for navigating to product pages.
Analysis of Surface cracks in CHQ gradesPiyush Verma
The analysis of Boron CHQ grade coils produced between January and April showed:
1. The 15B25 grade had the highest rejection rates, with over 60% of coils rejected in some heats.
2. Coils of diameter 5.5mm-10mm saw the most rejections, particularly for the 10B21 and 15B25 grades.
3. Some heats like 72754 and 73338 for the 15B25 grade had over 50% of coils rejected, indicating inconsistencies in the production process for these heats.
This document provides instructions for performing oxy-acetylene welding. It outlines the necessary equipment including an oxy-acetylene welding rig, goggles, pliers, and wire brush. The materials are listed as mild steel plates. Safety procedures are described such as wearing protective equipment and knowing the location of emergency equipment. The document then explains the oxy-acetylene welding process and provides step-by-step instructions for welding two steel plates together, including igniting the torch and controlling the molten weld pool. Assessment criteria for evaluating the quality of the welds are also presented.
409 is a titanium stabilised ferritic stainless steel. It forms a light protective rust layer in exhaust gas atmospheres and is readily weldable. Bhavya Steel is one the known suppliers and stockiest of stainless steel 409 sheets plates and coils.in Mumbai with various grades and specifications
TALAT Lecture 4107: General Summary and Future TrendsCORE-Materials
This lecture points out the need of data sources for designing mechanical joints; it describes concepts for FEM-Modelling of mechanical joints. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lectures 4101- 4106 is assumed.
TALAT Lecture 2711: Design of a Helicopter DeckCORE-Materials
This document provides a 3-page summary of the design of an aluminum alloy helicopter deck, including:
1) An overview of the main structural parts, loads, and material properties considered in the design.
2) An analysis of the deck extrusion profile using finite element modeling to check deflections and stresses. The original profile is modified to improve its performance.
3) An analysis of the welded I-beam support structure to check its capacity to resist bending moments from landing loads. Different beam depth options are considered.
4) A brief discussion of a bolted connection design for the support structure.
The document includes calculations to check that structural components satisfy strength and serviceability limit states according
SHEET METAL PART QUALITY IMPROVEMENT THROUGH DIE OPTIMIZATION USING AUTOFORMFarhad ZHalehfar
This document discusses using AutoForm to optimize sheet metal part quality through die optimization. It aims to improve simulation accuracy, standardize simulations, and transition die quality improvement to earlier design stages. This helps decrease part development time and costs. The document outlines past issues, optimization methodology, effective simulation parameters, verification of simulation results against experiments, and examples of optimized sample parts showing quality improvements and successful high production rates after die surface optimization based on simulations.
Tipo Global Corp is a sheet metal manufacturing company that offers OEM/ODM design and tooling, manufacturing, inspection, and logistic services. They have 30 years of experience in high-mix, low-volume production of sheet metal components for electronic machinery, cases, frames, and T5 luminaires. Their equipment includes punch presses, laser cutters, automatic welders, and presses. They produce parts from steel, iron, and aluminum sourced from top Taiwanese suppliers.
This lecture helps to understand how the properties of forgings evolve during the manufacturing process. General understanding of metallurgy and deformation processes is assumed.
This lecture provides a background on aluminium alloys suitable for impact extrusion. It draws attention to raw material parameters which may affect the properties of impact extruded parts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
This lecture describes the factors important for the quality assurance of adhesive joining; it gives information about the destructive and non-destructive testing methods for the quality control of adhesive joining. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
This lecture describes fabrication processes for superplastic forming, i.e. female and male die forming, and the criteria for selecting the correct process. General background in production engineering and material science is assumed.
TALAT Lecture 2301: Design of Members Example 4.4: Bending moment resistance ...CORE-Materials
This 3 sentence summary provides the key details about the document:
1) The document is a 10 page example from a lecture on designing members for bending moment that analyzes the bending moment resistance of a welded hollow section with outstands using a class 4 cross section.
2) It presents the geometry, material properties, nodes, and elements of the hollow cross section and performs iterative calculations of the effective cross section area, stress distribution, and effective thicknesses accounting for any heat affected zones to determine the bending moment resistance.
3) The example is considered comprehensive because it shows calculations in detail, covers all classes of cross sections, and demonstrates how to increase effective thickness for non-fully stressed elements through
TALAT Lecture 4205: Testing Methods for Welded JointsCORE-Materials
This lecture gives information about the relevant non-destructive and destructive testing methods for aluminium welded joints. Background in production welding and quality assurance is assumed.
TALAT Lecture 3503: Finishing and other Supplementary OperationsCORE-Materials
This lecture describes supplementary fabrication measures for impact extruded parts and gives some examples of finished impacts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
TALAT Lecture 5104: Basic Approaches to Prevent Corrosion of AluminiumCORE-Materials
This lecture describes important measures for the prevention of corrosion of unprotected, bare
aluminium. Basic knowledge of corrosion behaviour of aluminium and some knowledge of the electrochemical nature of corrosion is assumed
TALAT Lecture 3801: Manufacturing Examples and FundamentalsCORE-Materials
This lecture describes the fundamentals of the superplastic behaviour phenomenon of aluminium alloys and the basic process parameters which govern the manufacturing of superplastic sheet metal parts. General background in production engineering and material science is assumed.
This document provides an overview of application characteristics for rivet and clinch joints. It discusses design considerations such as choosing rivet diameters and distances from edges. It also covers material and tooling parameters that influence joint quality like surface finish. Testing methods are described for shear-tensile, fatigue, and impact tests. Sample geometries and results are shown. Finally, it briefly discusses cost considerations for different joining technologies.
TALAT Lecture 2301: Design of Members Example 5.5: Axial force resistance of ...CORE-Materials
This 3-page document provides an example calculation for determining the axial force resistance of a laced column. It includes dimensions, material properties, and calculations of various parameters needed for the analysis. Key steps and results are shown, such as determining the effective length, flexural buckling resistance, and checking that the lacing can resist the required shear force. In the end, it is determined that the lacing can adequately resist the applied axial load of 270 kN.
TALAT Lecture 3505: Tools for Impact ExtrusionCORE-Materials
This lecture provides knowledge about design philosophy and tool materials for impact tools, which are a cost factor and eminently important for successful impact extrusion. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
This lecture describes the detailed processes of single-step and multiple-step clinching; it shows the differences of the various clinching methods concerning the amount of shearing; it illustrates the major differences in mechanical properties of clinch joints compared with resistance spot welds. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lecture 4101 is assumed.
TALAT Lecture 4703: Design and Calculation of Adhesive JointsCORE-Materials
This lecture describes the basic types of loadings of adhesive joints and to give examples of recommended joint designs; it shows how to calculate the strength of adhesive joints. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
TALAT Lecture 4702: Factors Influencing the Strength of Adhesive JointsCORE-Materials
This lecture describes the factors governing the strength of adhesive joints in order to appreciate these factors for the design of adhesively bonded joints, i.e. geometry of joint, stiffness and strength of the adjoining parts, stress distribution in the adhesive layer as well as the effects of humidity and ageing. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
TALAT Lecture 1302: Aluminium Extrusion: Alloys, Shapes and PropertiesCORE-Materials
This lecture provides sufficient information on the extrusion of aluminum and the performance of extruded products to ensure that students, users and potential users of those products can understand the fabrication features that affect properties and economics. It shows how, in consequence, alloy choice for any end application depends not only on the characteristics required for that end use but also on production requirements. General knowledge in materials engineering and some knowledge about aluminium alloy constitution and heat treatment is assumed.
Headquartered at Kolkata, West Bengal, India, EMC Limited, was established in the year 1953 and today it is listed amidst the renowned producers and suppliers of Industrial Aluminum Alloy & Forged Products, Defense Components and Con Rods Spare. apart from this, our company blessed with certification is also involved in offering Substation Work and Turnkey Projects for Transmission Line Construction. We are an eminent firm and one of the pioneers of this domain that involves fabrication of products like Aluminum Alloy Extruded Rods, Aluminum Alloy Extruded Flats, Automotive Parts Forging, Kick Starters Forgings, Con Rods, etc.
This document provides information on aerospace-grade aluminum alloys 6061 and 2024, including their chemical compositions, typical mechanical properties, specifications, and characteristics. Alloy 6061 is the most versatile and least expensive, with good mechanical properties, corrosion resistance, and workability. It can be fabricated and welded using many common techniques. Alloy 2024 has high strength and fatigue resistance, making it suitable for applications requiring a good strength-to-weight ratio, though it has relatively poor corrosion resistance and welding is not recommended. Typical applications for each alloy are also outlined.
A Review on Optimization of the Process Parameters in Friction Stir Welding o...IJAEMSJORNAL
This study is describing a simple and systematic methodology for optimizing the Process parameters of friction stir welding (FSW) of (AA6105 and AA6082) aluminium alloy using Taguchi technique. The main focus of this review paper is to discuss FSW principle, process parameter and mechanical properties. The current study focuses on the friction stir welding of wrought aluminium alloys 6082 and aluminium alloy 6105 that are commonly used in the structural and automotive industries. Apart from this paper FSW process has been done on various aluminium alloys but dissimilar friction stir welding of these two materials are not reported in their research. A systematic study has been performed on the joint properties on the dissimilar welding of the selected materials and their relationships between various parameters.
TALAT Lecture 4400: Introduction to Friction, Explosive and Ultrasonic Weldin...CORE-Materials
This document provides an overview of friction, explosive, and ultrasonic welding processes for aluminium. It describes the basic principles of each process, including how friction welding uses rotation and pressure to generate heat, explosive welding uses shock waves to join materials, and ultrasonic welding uses ultrasonic vibrations. It also discusses parameters for welding different material combinations like aluminium to steel. Diagrams show macrostructures and hardness curves for joined regions. The document aims to introduce these welding techniques and their applications for joining aluminium.
IRJET- Investigation of Microstructural Features and Mechanical Propertie...IRJET Journal
This document investigates the effect of process parameters like pouring temperature, mold rotational speed, and melt treatments on the microstructure and mechanical properties of aluminum-silicon alloys produced via horizontal centrifugal casting. Testing found that optimum properties, like highest tensile strength and hardness, resulted from a pouring temperature of 700°C and mold rotational speed of 1050 rpm. The addition of grain refiners and modifiers to the melt improved properties by refining the microstructure. Microstructural analysis showed that higher rotational speeds produced finer microstructures with increased solidification rates. Overall, the study aims to determine processing conditions that maximize the mechanical properties of aluminum-silicon alloys for automotive applications.
The document provides information on 11 aluminum die casting alloys, including their chemical compositions, typical material properties, die casting characteristics, and applications. It states that Alloy A380 is the most widely used due to its favorable properties and ease of production. The other alloys have specialized characteristics making them more suitable for specific applications like intricate components, high strength at elevated temperatures, corrosion resistance, or pressure tightness. The document provides detailed tables on the chemical compositions, material properties, and die casting/machining characteristics of each alloy to help guide alloy selection for different design needs.
This document provides information on TRIP (TRansformation Induced Plasticity) steels from ArcelorMittal, including descriptions, applications, standards, availability, processing recommendations, and mechanical properties. TRIP steels offer high strength and ductility from their microstructure composed of islands of retained austenite and bainite in a ferritic matrix. They are suitable for automotive structural and reinforcement parts. The document discusses grades, coatings, formability, welding parameters, fatigue strength, and impact performance of TRIP steels. Technical support is available from ArcelorMittal for incorporating these steels.
Characterization on Aluminium Alloy 7050 Metal Matrix Composite Reinforced wi...IRJET Journal
This document summarizes research characterizing an aluminum alloy 7050 metal matrix composite reinforced with 6% titanium dioxide. The composite was fabricated using stir casting and was characterized in terms of its mechanical properties, microstructure, and how these compare to the base alloy 7050. Testing showed the composite had improved tensile strength, compression strength, and hardness over the base alloy. Microstructural analysis revealed a uniform distribution of titanium dioxide particles in the aluminum matrix.
IMPACT ANALYSIS ON ALUMINIUM AND MAGNESIUM 5 SPOKE ALLOY WHEEL USING FEAIRJET Journal
This document discusses the finite element analysis of 5-spoke aluminum and magnesium alloy wheels. It begins with an introduction to alloy wheels and the material properties of A356 aluminum alloy and AZ91 magnesium alloy. It then describes the modeling of a 5-spoke wheel in SOLIDWORKS. The wheel model is imported into ANSYS for finite element analysis under impact loading conditions. The results show that the magnesium alloy wheel experiences greater total deformation, equivalent stress, and equivalent elastic strain compared to the aluminum alloy wheel. In conclusion, aluminum alloy wheels are found to be more durable than magnesium alloy wheels for regular vehicle use.
FINAL REVIEWADAFASFSAFASFAFSFSGGaGGV HBKJSJohn Ajish
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Chapter wise All Notes of First year Basic Civil Engineering.pptxDenish Jangid
Chapter wise All Notes of First year Basic Civil Engineering
Syllabus
Chapter-1
Introduction to objective, scope and outcome the subject
Chapter 2
Introduction: Scope and Specialization of Civil Engineering, Role of civil Engineer in Society, Impact of infrastructural development on economy of country.
Chapter 3
Surveying: Object Principles & Types of Surveying; Site Plans, Plans & Maps; Scales & Unit of different Measurements.
Linear Measurements: Instruments used. Linear Measurement by Tape, Ranging out Survey Lines and overcoming Obstructions; Measurements on sloping ground; Tape corrections, conventional symbols. Angular Measurements: Instruments used; Introduction to Compass Surveying, Bearings and Longitude & Latitude of a Line, Introduction to total station.
Levelling: Instrument used Object of levelling, Methods of levelling in brief, and Contour maps.
Chapter 4
Buildings: Selection of site for Buildings, Layout of Building Plan, Types of buildings, Plinth area, carpet area, floor space index, Introduction to building byelaws, concept of sun light & ventilation. Components of Buildings & their functions, Basic concept of R.C.C., Introduction to types of foundation
Chapter 5
Transportation: Introduction to Transportation Engineering; Traffic and Road Safety: Types and Characteristics of Various Modes of Transportation; Various Road Traffic Signs, Causes of Accidents and Road Safety Measures.
Chapter 6
Environmental Engineering: Environmental Pollution, Environmental Acts and Regulations, Functional Concepts of Ecology, Basics of Species, Biodiversity, Ecosystem, Hydrological Cycle; Chemical Cycles: Carbon, Nitrogen & Phosphorus; Energy Flow in Ecosystems.
Water Pollution: Water Quality standards, Introduction to Treatment & Disposal of Waste Water. Reuse and Saving of Water, Rain Water Harvesting. Solid Waste Management: Classification of Solid Waste, Collection, Transportation and Disposal of Solid. Recycling of Solid Waste: Energy Recovery, Sanitary Landfill, On-Site Sanitation. Air & Noise Pollution: Primary and Secondary air pollutants, Harmful effects of Air Pollution, Control of Air Pollution. . Noise Pollution Harmful Effects of noise pollution, control of noise pollution, Global warming & Climate Change, Ozone depletion, Greenhouse effect
Text Books:
1. Palancharmy, Basic Civil Engineering, McGraw Hill publishers.
2. Satheesh Gopi, Basic Civil Engineering, Pearson Publishers.
3. Ketki Rangwala Dalal, Essentials of Civil Engineering, Charotar Publishing House.
4. BCP, Surveying volume 1
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Temple of Asclepius in Thrace. Excavation resultsKrassimira Luka
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2. 3705 Drawing of Automotive Sheet Metal Parts
Table of Contents
3705 Drawing of Automotive Sheet Metal Parts.............................................2
3705.01 Introduction................................................................................................ 3
3705.02 Characteristic Materials Parameters ....................................................... 4
Effect of Paint Bake Cycle on Strength ...................................................................4
Anisotropy................................................................................................................4
3705.03 The Drawing Process ................................................................................. 6
Stretch Forming .......................................................................................................6
Stretch Forming a Bulge with a Spherical Punch ....................................................7
Hydraulic Stretch Forming.......................................................................................8
Deep Drawing with a Hemispherical Punch ..........................................................10
Deep Drawing and Stretch Forming ......................................................................11
Drawing Irregular Sheet Shapes of Large Areas....................................................12
3705.04 Possibilities of Controlling the Material Flow....................................... 13
Control of Material Flow under Blankholder ........................................................13
Arrangement of Draw Beads..................................................................................15
3705.05 Adjusting the Die Cushion ....................................................................... 15
Mechanical vs. Hydraulic Press Equipment ..........................................................15
Four-Point Die Cushion .........................................................................................16
Desired and Actual Curves for Blankholder Force ................................................17
Advantages of a Servo-Hydraulic Die Cushion in the Press Table .......................17
Four-Point Die Cushion in the Press Table............................................................18
Four-Point Die Cushion in the Press Table with Adjustable Spindle Sleeves.......19
Functional Principle of a Spindle Sleeve Adjustment ...........................................20
Experimental Construction of a Single Action Hydraulic Press (10-Point) ..........20
Blankholder and Spindle Sleeve Forces.................................................................21
Force Displacement Curves ...................................................................................21
Demonstration Case of the Multi-Point Drawing Arrangement ............................24
3705.06 Tool Materials for Drawing of Aluminium Sheet Metal Parts ............ 25
Tool Materials........................................................................................................25
Surface Coatings for Drawing Tools .....................................................................26
3705.07 Examples................................................................................................... 27
3705.08 List of Figures............................................................................................ 29
TALAT 3705 2
3. 3705.01 Introduction
Forecasts for the year 2000 predict that the proportion of steel used in cars will shrink
compared to 1984. At the same time the proportion of high strength steel will increase
sharply as will the share of automotive aluminium, see Figure 3705.01.01.
Forecast for the Year 2000
%
65
Steel
Steel
60
high-strength
50 and
higher strength
40 steel
30
20
Plastics
10 Plastics Aluminium Aluminium
0
1984 2000
Source: Thyssen technical reports 2/86
alu
Training in Aluminium Application Technologies
Forecast for the Year 2000 3705.01.01
Among other applications in the car, aluminium alloys will be used to substitute steel in
carbody sheet components. Previous experience with the production of aluminium sheet
metal components for cars has demonstrated that special attention has to be given to the
peculiarities of aluminium carbody sheet in the fabrication of car components. The fab-
rication process of carbody sheet metal components is a mixture of deep drawing and
stretch forming. Aluminium and steel behave differently with regard to these two basic
forming operations. It is, therefore, necessary to consider the basic technology of sheet
metal drawing for aluminium carbody components in view of the material properties,
the behaviour during the drawing process and the special requirements with respect to
the drawing equipment and the tooling.
TALAT 3705 3
4. 3705.02 Characteristic Materials Parameters
Effect of Paint Bake Cycle on Strength
Figure 3705.02.01 shows the influence of cold forming and paint stoving on the yield
stress Rp0,2 of typical aluminium carbody sheet alloys. It is apparent that age-hardening
alloys profit from the baking cycle while strain-hardening alloys may suffer a reduction
in yield strength values.
Influence of Cold Work and Simulated
Lacquer Stoving (205 °C/ 30 min.) on Yield Strength
300
6009-T4 after stoving
2
N/mm
250
Yield strength Rp0,2
6009-T4 before stoving
200 5182-O
150
5182-O after stoving
100
0 1 2 3 4 5 6 7 % 8
Cold Work (Strain)
Source: IFU Stuttgart
alu Influence of Cold Work and Simulated
Training in Aluminium Application Technologies Lacquer Stoving on Yield Strength 3705.02.01
Anisotropy
Figure 3705.02.02 shows the yield criteria for a plane state of stress as a function of the
r value. A value of r = 1 indicates an isotropic behaviour.
Under a tensile-compressive state of stress, as in the flange of a deep drawn part, the
stress required to maintain a plastic state decreases with increasing values of r. This
means that increasing values of r result in lower drawing forces.
During tensile-tensile stressing, e.g. in the body of a deep drawn part, larger axial
stresses can be transmitted with increasing values of r.
By increasing the value of r, one can increase the strength of the body and at the same
time lower the strength in the flange. This explains why the limiting draw ratio increases
with increasing r values.
TALAT 3705 4
5. Aluminium sheet alloys in a state of good drawing quality generally have values of r ≤ 1
which vary with respect to the rolling direction.
Effects of Anisotropy
!"
I
! # %& r=5
IV
kf r=3
r = 1, ∆ r = 0
-kf r=0
!1
kf
-kf II
III
alu
Training in Aluminium Application Technologies
Effect of r-Value on Yield Locus 3705.02.02
Figure 3705.02.03 illustrates the elongation values Ag and A80 for the alloy
AlMgSi1-ka (EN-AW 6082-T4) using polar coordinates.
Elongation Values for AlMgSi1-ka
in polar coordinates
Rolling direction (RD)
0° 22.5° 45°
%
30
%
15 67.5°
90°
to RD
Ag
A80mm
Source: IfU Stuttgart
alu
Training in Aluminium Application Technologies
Elongation Values for AlMgSi1-ka in Polar Coordinates 3705.02.03
Figure 3705.02.04 shows the vertical anisotropy r for the alloy AlMg5Mn-w (EN-AW
5182-0) using polar coordinates.
TALAT 3705 5
6. Vertical Anisotropy r for AlMg5Mn w
as a function of rolling direction
Rolling direction (RD)
0° 22.5° 45°
1.0
67.5°
0.4
r90° = 0.640
90°
to RD
r0° = rmin' 0.592
r45° = rmax' 0.934
r value for ϕg = 0.11
Source: IFU Stuttgart
alu Vertical Anisotropy r for AlMg5Mn w
Training in Aluminium Application Technologies as a Function of Rolling Direction
3705.02.04
The varying elongation behaviour and the varying values for anisotropy are a result of
the texture of the individual materials. The values shown here are exemplary and depend
on the material as well as on the processes of cold and warm rolling and on the heat
treatment.
3705.03 The Drawing Process
Stretch Forming
Basic elements of stretch forming are shown in Figure 3705.03.01. During stretch form-
ing, the sheet is clamped on two sides. As a result, the increase in the sheet surface area
due to the activation of the punch, is accompanied by a decrease in sheet thickness. A
tensile state of stress exists. The forming zone starts at the clamping grips and proceeds
to the punch middle. In order to ensure that, in spite of the hindering action of the fric-
tion, even this portion of the sheet is strained, it is desirable to keep the coefficient of
friction between sheet blank and punch low and to have a high strain hardening coeffi-
cient.
TALAT 3705 6
7. Stretch Forming
µ Sheet blank
Gripping jaws (clamps)
' Two-sided clamping Stretching forming punch
' Due to rigid clamping, increase of surface compensated for by decrease in sheet thickness
with little participation of parts not under tension.
' The forming zone spreads out, starting from the end of the gripping jaw to the middle
of the forming punch.
Aims:
' As small a coefficient of friction µ as possible between sheet and forming punch.
' A high strain hardening coefficient n
Source: IFU Stuttgart
alu
Training in Aluminium Application Technologies
Stretch Forming 3705.03.01
Stretch Forming a Bulge with a Spherical Punch
Figure 3705.03.02: During the stretch forming of a bulge with a spherical punch the
blank is clamped firmly under the blankholder so that no material can flow in from the
flange to supply material for the increasing surface area during drawing. The enlarge-
ment of the hemispherical surface area can only be achieved by a decrease in sheet
thickness.
Mechanical drawing
FSt + FK FSt + FK
µ
h Drawing ring
Blankholder
d0
FK FK
Drawing punch (forming block)
FSt
- Clamping force FK prevents flowing-in of sheet
- All-around clamping
- Forming zone spreads out from clamping location to punch dome
- Increase of surface area compensated for only by decrease in thickness.
Aims: - rmin large
- ∆r small
- n large
Coefficient of friction µ between sheet and punch should be kept small.
Source: IFU Stuttgart
alu
Training in Aluminium Application Technologies
Mechanical Drawing 3705.03.02
TALAT 3705 7
8. The forming zone starts at the clamping grips and proceeds to the spherical punch pole.
For this stretch forming process it is desirable to have as low a value of ∆r as possible
and as high a value of rmin and strain hardening coefficient n as possible. The coefficient
of friction between sheet and punch should be kept low.
Strain-Path Curves for Mechanical Drawing
Stretch forming with a hemispherical punch
Lubricant: uncompounded oil 300 cSt/ 40°C
50
point 18
point 15
point 12
40
point 9
P
FR point 6
12
30
9 Tear depth 36.5 mm
18 36.5 mm
15 15
ϕ1 [1]
Tear 12
20 30 mm
9
6 20 mm
18
10 6
10 mm
0
0 10 20 30 40 50
Source: W.Karsunke ϕ2 [1]
alu
Training in Aluminium Application Technologies
Strain-Path Curves for Mechanical Drawing 3705.03.03
Figure 3705.03.03 illustrates the traces of the principal strains at different locations of
the drawn bulge during stretch forming with a hemispherical punch. The traces of strain
from locations 9 and 12 approach the forming limit curve closest. Not surprisingly, tear-
ing occurs at a location next to these points on the bulge.
Hydraulic Stretch Forming
During hydraulic drawing, the blank is clamped all around its edges so that the forming
zone is the portion within the drawing ring, see Figure 3705.03.04. Like in the previous
case, the increase in surface area has to be compensated for by a decrease in the sheet
thickness.
As far as the characteristic sheet values are concerned, large values for rmin and low
values for ∆r are desirable. The strain hardening coefficient n should be as high as pos-
sible.
TALAT 3705 8
9. Hydraulic FK + Fu
d0
FK + Fu
drawing
h Drawing ring
Base plate
πd0
2
PHydr. Fu = PHydr.
FN + Fu FN + Fu 4
- Clamping force FK prevents flowing-in of sheet
- All-around clamping
- Forming zone equal to sheet region included in drawing ring
- Increase of surface area compensated for only by decrease in thickness.
Aims: - rmin large
- ∆r small
-n large
Source:IFU Stuttgart
alu
Training in Aluminium Application Technologies
Hydraulic Drawing 3705.03.04
Figure 3705.03.05 illustrates the traces of the principal strains at different locations on
the drawn part during hydraulic stretch forming. One notices that the differences be-
tween the individual measuring locations is much smaller than for mechanical buldge
drawing, indicating that the deformation strain is much more uniformly distributed over
the component.
Strain-Path Curves for Hydraulic Drawing
50
18 point 18
point 15
point 12
40
point 9
15 point 6
30 Tear
Tear depth 36.5 mm
18 36.5 mm
12 15
ϕ1 [1]
12
20 30 mm
9
9
20 mm
6
10 6
10 mm
0
0 10 20 30 40 50
Source: W.Karsunke ϕ2 [1]
alu
Training in Aluminium Application Technologies
Strain-Path Curves for Hydraulic Drawing 3705.03.05
TALAT 3705 9
10. In Figure 3705.03.06, the principal strains ϕg for mechanical and hydraulic drawing are
compared.
Comparison of the Principal Strains ϕg
for Mechanical and Hydraulic Drawing
1.00
0.80 10 cSt/40°C
Stretch forming
100 cSt/40°C with hemispherical
300 cSt/40°C punch
ϕg [1]
0.60
hydraulic drawing
0.40
18
0.20
30 mm
1 35
0
1 5 10 15 18 20 25 30 35
Location of measuring points over hemisphere 100
Source: W.Karsunke
alu Comparison of the Principal Strains ϕg
3705.03.06
Training in Aluminium Application Technologies for Mechanical and Hydraulic Drawing
Deep Drawing with a Hemispherical Punch
Figure 3705.03.07: In deep drawing with a hemispherical punch, the forming zone
covers the region between the flange outer edge and the location where the drawing part
leaves the drawing ring curvature. In contrast to stretch forming, the surface areas of the
blank and the drawn part are about the same, so that the sheet thickness remains almost
constant.
The blankholder force prevents the formation of „type 1“ folds. The base of the drawing
part is formed according to the principle of mechanical drawing.
As far as the characteristic sheet values are concerned, large values for rmin and low
values for ∆r are desirable. The strain hardening coefficient n should be as high as pos-
sible.
The coefficients of friction µ for the combinations punch/lubricant/sheet, blankholder/
lubricant/sheet, drawing ring/lubricant/sheet and drawing ring rounding/lubricant/sheet
should be as low as possible.
TALAT 3705 10
11. FSt + FN FSt + FN
Deep Drawing
with a
h Drawing ring
hemispherical punch
d0
D Blankholder
- blankholder force FN prevents
type 1 folds. FN FN
Drawing punch
- Forming zone is the sheet area between FSt
flange outer diameter (D = f(h))
and the location at which the sheet Aims: - rmin large
leaves the drawing ring curvature (d0). - ∆r small
- Surface area of drawn part is -n large
approximately equal to the surface area
of the original blank. Consequently, Coefficients of friction should be kept small
sheet thickness is almost constant. for the following combinations:
hemisspherical punch surface / lubricant / sheet,
- Dome (bottom of part) is formed
blankholder / lubricant / sheet,
by stretch forming
drawing ring / lubricant / sheet and
drawing ring rounding / lubricant / sheet.
Source: IFU Stuttgart
alu
Training in Aluminium Application Technologies
Deep Drawing with a Hemispherical Punch 3705.03.07
Deep Drawing and Stretch Forming
Figure 3705.03.08 shows two separate schematics for the comparison of the deep draw-
ing and stretch forming processes for a flat bottomed cup.
Deep drawing and stretch forming
Deep drawing Stretch forming
alu
Training in Aluminium Application Technologies
Deep Drawing and Stretch Forming 3705.03.08
TALAT 3705 11
12. Sheet metal parts with large surface areas are usually formed using a combination of
deep drawing and stretch forming.
A state of pure stretch forming exists only in very few cases. In such cases, the outer
edge of the blank is clamped so that the increase in surface area can only come out of
the sheet thickness.
Deep drawing is the other extreme in which the blankholder holds the sheet so that it
can flow in during forming. The sheet thickness remains approximately constant and the
surface areas of the shaped part and the starting blank are about the same.
Drawing Irregular Sheet Shapes of Large Areas
Two types of drawing beads are shown in the Figure 3705.03.09. The clamping beads
have a rectangular section and absolutely prevent any sheet material from flowing in.
Brake rolls serve only to create an additional forming work.
Drawing Irregular Sheet Shapes of Large Areas
Blank form
Drawing frame
alu
Drawing Irregular Sheet Shapes of Large Areas 3705.03.09
Training in Aluminium Application Technologies
TALAT 3705 12
13. 3705.04 Possibilities of Controlling the Material Flow
In processes which are not purely deep drawing but consist instead of a combination of
deep drawing and stretch forming, it is necessary to control the flow of material under
the blankholder. This can be achieved using different methods, individually or in com-
binations.
Control of Material Flow under Blankholder
Control of material flow
under the blankholder
Influence of
Blank form Lubricant Crimp frictional forces
Blankholder force
FN
drawing crimp
- type
- amount Draw path S
- distribution clamping crimp
Source: IFU Stuttgart
alu
Training in Aluminium Application Technologies
Control of Material Flow Under Blankholder 3705.04.01
Figure 3705.04.01 shows a number of possibilities for controlling material flow under a
blankholder:
Blank form
Large sheet blank areas under the blankholder require large forming forces.
Lubricants
One method is to use a blank with nonuniform lubrication, i.e, different lubrication con-
ditions at different locations of the blank, before drawing. Another method is to use a
blank with a uniform basic lubrication which is then locally enhanced at chosen places
by lubricating jets arranged in the tool, i.e., before each pressing stroke, an additional
local lubrication effect exists between sheet and work-piece.
TALAT 3705 13
14. Clamping crimps
Clamping crimps hinder the flowing in of the material to varying degrees, depending on
the form and size. It is thus possible to reduce the blankholder force, whereby the draw-
ing force is increased.
Influencing the frictional forces
By regulating the blankholder force, it is possible to enhance or hinder the flow of mate-
rial under it. This effect is obtained by locally varying the distance between blankholder
and drawing frame, so that higher contact pressures can be brought to bear where the
distance is smaller.
Another possibility of controlling the material flow and consequently the deformation
strain distribution during the drawing of irregular sheet shapes with varying draw
depths, is by using brake rolls and draw beads. These hinder the flow of material by
varying amounts, depending on their form and size. Again, it is possible to reduce the
blankholder force, whereby the drawing force increases.
As a result of the brake action of the draw beads, the material can no longer freely flow
over the draw ring radius into the draw gap during the forming process. Thus it is possi-
ble to reduce the stress differences between side walls and corner regions for compli-
cated irregular shapes as well as for square shaped drawn parts.
By optimally arranging the draw beads, one can control the material flow to create a
uniform stress distribution such as occurs while fabricating cylindrical shapes. Brake
rolls and draw beads ensure that the resistance of material flow over the draw ring radius
into the draw gap varies locally, thus simulating the effect of increasing blankholder
pressure.
Depending on the design and arrangement in the tool, one can differentiate between
draw beads and brake rolls.
Draw beads are arranged at some distance from the drawing ring radius and cause, to-
gether with the die radius, a three-fold directional change of the sheet. Draw beads can
be arranged in both slanting and straight blankholder surfaces.
Brake rolls are arranged at the die shoulder and create a two-fold directional change of
the sheet material. Brake rolls in the draw ring are used mostly for round or oval sheet
shapes with a parabolic or similar casing form.
TALAT 3705 14
15. Arrangement of Draw Beads
Figure 3705.04.02 shows the arrangement of draw beads for a drawn carbody compo-
nent.
Arrangement of draw beads
10°
10° 10°
a
b
a b
Source: IfU Stuttgart
alu
Training in Aluminium Application Technologies
Arrangement of Draw Beads 3705.04.02
3705.05 Adjusting the Die Cushion
Mechanical vs. Hydraulic Press Equipment
During drawing with a mechanical double-acting press (press with drawing punch ram
and blankholder ram), the blankholder can be locally adjusted at the four points under
the crank so that different contact pressures can be applied at the locations front left,
front right, rear left and rear right under the blankholder, Figure 3705.05.01. A regula-
tion, if at all possible, can only be carried out as far as the pressure is concerned.
With the double-acting hydraulic press it is possible, without any great effort, to regulate
the blankholder force during the draw path at each corner point, since each corner point
has its own hydraulic cylinder.
TALAT 3705 15
16. Double action press Single action press Single action press
with pneumatic drawing with hydraulic drawing
equipment in the press table equipment in the press table
a a a
b
c e e
d d d
e c c
f
f f
g
h
~ 20 x 4x
a) Ram b) Blankholder ram c) Drawing punch d) Blankholder e) Counter pressure
f) Mounting plate g)Hydraulic cylinder h) Air-cushion pins
Source: IFU Stuttgart
alu
Training in Aluminium Application Technologies
Drawing Equipment 3705.05.01
Four-Point Die Cushion
Four-point drawing equipment
press ram
tool top part
blank
bottom drawing frame
(blankholder)
drawing tool
tool plate
tool mounting plate
table plate
hydraulic cylinder (4x)
proportional valve
Source: IFU Stuttgart
alu
Training in Aluminium Application Technologies
Four-Point Drawing Equipment 3705.05.02
TALAT 3705 16
17. Figure 3705.05.02 together with the Figure 3705.05.01 illustrate that it is possible to
draw parts using a three-piece tool not only with a two-fold acting press but also with a
simple acting press. In these cases, the blankholder (lower drawing frame) is supported
on a drawing form plate (cushion) form with the help of a number of pressure bolts.
This drawing form plate is moved up and down or subjected to the blankholder force
with the help of pneumatic or hydraulic cylinders.
Desired and Actual Curves for Blankholder Force
When the top frame contacts the blank lying on the lower frame, an undesirable force
peak occurs, causing the lubricant film to break down, Figure 3705.05.03. In addition,
this causes an undesirable overloading of the tool and machine and is a cause of noise.
This undesirable force peak can be avoided by starting the drawing process with a lower
pressure in the cylinders and then increasing this pressure to a level which prevents the
formation of type-1 folds and allows the necessary material flow to be regulated.
1000 1000
900 900
Force [kN]
800 800
Force [kN]
700 Required curve 700 Required curve
600 600
500 500
400 400
300 300
200 200
100 100
0 0
1000 1000
900 900
Actual curve Actual curve
Force [kN]
800 800
Force [kN]
700 700
600 600
500 500
400 400
300 300
200 200
100 100
0 0
210 120 60 15 0 Ram path 210 120 60 15 0 Ram path
before UT [mm] before UT [mm]
120 135 150 165 180 Crank angle [°] 120 135 150 165 180 Crank angle [°]
Source: IfU, Stuttgart UT UT
alu
Training in Aluminium Application Technologies
Desired and Actual Curves for Blankholder Force 3705.05.03
Advantages of a Servo-Hydraulic Die Cushion in the Press Table
Figure 3705.05.04 summarises the advantages of a die cushion in the press table of a
simple acting press over the mechanical double acting press with a drawing ram and a
blankholder ram:
− No overturning operations required between drawing press and trimming press
necessary.
TALAT 3705 17
18. − Reduction of the force peaks during initial contact between the top frame and the
sheet blank lying on the bottom frame.
− Control of the blankholder force, i.e., the material flow over the draw path.
− Reproducible press operation
Advantages of a Servo Hydraulic Die Cushion
in the Press Table
A servo hydraulic die cushion in the press table of a simply acting press table
has following advantages over a two-fold acting mechanical press with drawing
ram and blankholder ram :
1. No overturning operations required between drawing press and trimming press.
2. Reduction of the force peak during contaction of the top frame and sheet blank
lying on the bottom frame.
3. Control of the blankholder force, i.e., the material flow over the draw path.
4. Reproducible press operation.
alu Advantages of a Servo Hydraulic Die Cushion
Training in Aluminium Application Technologies in the Press Table 3705.05.04
Four-Point Die Cushion in the Press Table
Four-point die cushion in the press table with
individually controlled and regulated hydraulic cylinders
Tool mounting
plate
Table plate
Hydraulic
cylinder
Proportional valve
Source: IFU Stuttgart
alu
Training in Aluminium Application Technologies
Four-Point Die Cushion in the Press Table 3705.05.05
The present trend is to produce large one-piece pressed shapes, e.g. complete automo-
bile side walls. Conventional four-point die cushion is, however, unsuitable for large
parts. One method of developing the die cushion is the possibility of utilising many cyl-
inders instead of four corner cylinders, Figure 3705.05.05. In order to prevent the regu-
TALAT 3705 18
19. lating and control mechanism from getting too complicated, the cylinders can be joined
together in groups which are controlled in unison.
Four-Point Die Cushion in the Press Table with Adjustable Spindle Sleeves
The Institut für Umformtechnik (institute for forming technology) of the University of
Stuttgart and the company Maschinenfabrik Müller-Weingarten have developed an al-
ternative method. In the construction shown in this Figure 3705.05.06 and Figure
3705.05.08, the force for the blankholder in the drawing frame is controlled by spindle
sleeves with integrated force gauges in which the spindle sleeves can be adjusted to dif-
ferent heights using a stored programme. The spindle sleeves are supported on a draw-
ing cushion which can be regulated and controlled by four hydraulic cylinders.
Spindle sleeve (pressure bolt)
Table plate
Spindle sleeve (presssure bolt)
adjustment
Die cushion plate
Guide for due cushion plate
Hydraulic cylinder
Proportional valve
Source: IFU Stuttgart
alu Four-Point Die Cushion in a Press Table with
Training in Aluminium Application Technologies Adjustable Spindle Sleeves 3705.05.06
With this design it is possible to maintain the reliable adjustment of the force-path curve
for each corner cylinder. By choosing the spindle sleeve to be activated, an adjustment
can be made to suit the drawing frame form. The spindle sleeves not required can re-
main in their normal position. By choosing the optimal spindle sleeve lengths, the tool
can be elasticly bent to compensate for the flexure of the drawing frame and drawing
cushion plate as well as for regulating the material flow by locally adjusting the contact
pressure.
TALAT 3705 19
20. Functional Principle of a Spindle Sleeve Adjustment
Figure 3705.05.07: The adjustable spindle sleeves are supported against pressure
gauges fitted on the drawing cushion plate. The spindle sleeves are adjusted by hydro
motors, belt drive and spline shaft, whereby the height adjustment is recorded on a mo-
ment controller.
Functional principle of a spindle sleeve adjustment
Spindle sleeve (pressure bolt)
Table plate
Spindle sleeve adjusting spindle
Force gauge
Drawing cushion plate
Spline shaft
Toothed belt drive
Moment controller
Hydro motor
Source: IFU Stuttgart, Müller-Weingarten AG
alu
Training in Aluminium Application Technologies
Functional Principle of a Spindle Sleeve Adjustment 3705.05.07
Experimental Construction of a Single Action Hydraulic Press (10-Point)
Figure 3705.05.08 shows the experimental construction of a single action hydraulic
press with a 10-point die cushion in the press table. For details refer to Figure
3705.05.06.
Experimental Construction of a
Single Action Hydraulic Press (10-Point)
extension gauges for
inductive path gauge punch force
with feeler pin for measurement
folds measurement
extension gauges for
flexure measurement
spindle sleeves (10)
force gauge for
measuring
blankholder force
drawing tool
hydraulic die
cushion
press table
Source: IfU Stuttgart fixing elements
Experimental Construction of a
alu
3705.05.08
Training in Aluminium Application Technologies Single Action Hydraulic Press (10-Point)
TALAT 3705 20
21. Blankholder and Spindle Sleeve Forces
Figure 3705.05.09 shows the blankholder and spindle sleeve forces acting on the draw-
ing cushion plate of a 10-point die cushion based on the principle of four corner point
cylinder forces Fvl (front left), Fvr (front right), Fhl (rear left) and Fhr (rear right). The
sum of these forces is equal to the sum of the active spindle sleeve forces FP1 to FP10.
Blankholder and spindle sleeve forces of a die
cushion plate of a 10-point drawing equipment
PN Lower drawing frame
FP10
FP6 FP7 FP8 FP9
FP5 FP4 FP3 FP2 FP1
Fhl Fhr
Die cushion plate
Fvl Fvr
FVl......Fhr : Controllable and adjustable blankholder forces
FP1.....FP10: Adjustable spindle sleeve forces
Source: IFU Stuttgart
alu
Training in Aluminium Application Technologies
Blankholder and Spindle Sleeve Forces 3705.05.09
Force Displacement Curves
Figure 3705.05.10 shows the force-displacement curves of the total blankholder force
FNtot (upper diagram) as well as for the four different blankholder forces (Fvr, Fhr, Fvl,
Fhl), which were pre-set in a five-step rising gradient, over the full drawing path. Fur-
thermore, it also shows the force-displacement curves for the four active spindle sleeves
( FP1, FP2, FP3, FP4) as a function of the drawing path. The formation of force peaks was
largely prevented by correctly pre-setting the individual force-displacement curves for
the four active spindles.
TALAT 3705 21
22. Force-Stroke Curves
Total blankholder force Spindle sleeve force
FNges FP2
kN FP9
800
200 FP4
kN
100 FP7
600
50 100 150 mm 200
400 Blankholder force
Fvr
kN
200 Fhr
200
Fvl
100
Fhl
0
50 100 150 mm 200 50 100 150 mm 200
Stroke Stroke
Source: IFU, Stuttgart
alu
Training in Aluminium Application Technologies
Force-Stroke Curves 3705.05.10
Figure 3705.05.11 shows the hydraulic simple-acting 4,000 kN press supplemented by a
10-point die cushion at the Institute of Forming Technology (IFU) of the University of
Stuttgart.
Hydraulic 4.000 kN
Sheet Forming Press
at the
Institut für Umformtechnik,
University of Stuttgart
Source: Müller-Weingarten Co.
alu
Hydraulic 4.000 kN Sheet Forming Press 3705.05.11
Training in Aluminium Application Technologies
TALAT 3705 22
23. The characteristics of a multi-point die cushion in the press table of a simple-acting
press with respect to the drawing process are summarised in Figure 3705.05.12.
Four-Point Die Cushion in the Press Table
of a Simple Acting Press
' Force application to the blankholder can be adjusted to be
most suitable for the tool.
' Material flow controlled by a defined elastic flexure of the
blankholder using a stored programmable height adjustment
of the spindle sleeves.
' Control and regulation of the blankholder force over the
stroke using four hydraulic cylinders and the proportional
valve technology.
' Reproducible operational behaviour of the die cushion.
alu Four-Point Die Cushion in the Press Table of a
Training in Aluminium Application Technologies Simple Acting Press 3705.05.12
Figure 3705.05.13 gives an example of a lower drawing frame.
Lower drawing frame ( I )
1700
840
Source: IFU Stuttgart
alu
Training in Aluminium Application Technologies
Lower Drawing Frame ( I ) 3705.05.13
TALAT 3705 23
24. Demonstration Case of the Multi-Point Drawing Arrangement
Figure 3705.05.14 shows the lower drawing frame with a four-point force transmission
for the forming of a rectangular cup. The flexural elastic deformation of this four-point
drawing frame can of course be simulated by FE-calculations.
Lower Drawing Frame (II)
Source: IFU Stuttgart
alu
Training in Aluminium Application Technologies
Lower Drawing Frame (II) 3705.05.14
1200
Tears
KN
FP6 FP7 FP8 FP9
FP10
1000
FP5 FP4 FP3 FP2 FP1
900 Extension
uniform optimal spindle of the
800 force level sleeve height
working
700 range
Total blankholder force
600
500
400
Working range
300
for good parts
200
100 Type 1 folds
0
0 20 40 60 80 100 120 140 mm 180
punch stroke
Source: IfU Stuttgart
alu
Optimal Working Range for Deep Drawing 3705.05.15
Training in Aluminium Application Technologies
Figure 3705.05.15 shows that the working range for deep drawing can be extended con-
siderably by the adjustment of the local blankholder pressure with the aid of the spindle
TALAT 3705 24
25. sleeves in a multi-point die cushion. The necessary adjustment of the blankholder force
distribution depends on the specific tool geometry and can be determined for each draw-
ing tool. The lower limit of the working range is a consequence of the formation of
„type 1“ folds in the draw part flange. The upper limit of the working range is a conse-
quence of the formation of tears in the region of the drawn part body. This working
range has to be determined anew for each sheet-lubricant combination.
With an optimal adjustment of the spindle sleeves in a multiple point die cushion, it is
possible to widen the working range for deep drawing and increase the draw depth.
3705.06 Tool Materials for Drawing of Aluminium Sheet Metal Parts
Tool Materials
Figure 3705.06.01 lists typical tool materials for drawing automotive steel and alumin-
ium sheet metal parts. As in the case of steel, the drawing tools for aluminium are of
grey cast iron quality. Experience has shown, however, that the surfaces of such materi-
als are not suitable for forming aluminium. The materials 1.0443 (GS 45) as well as
1.2769 (GS 45 Cr Ni Mo 4 2) are more suitable, since better surface finishes can be ob-
tained, which in turn reduce the tendency for wear and cold weld adhesion. The alumin-
ium bronze AMPCO also has very good gliding properties.
Tool Materials
Steel sheet:
0.6025 (GG 25 Cr Mo)
1.2080 (X 210 Cr 12)
1.2379 (X 155 Cr V Mo 12 1)
Aluminium:
1.0443 (Gs 45)
1.2769 (G 45 Cr Ni Mo 42)
The tool materials listed for aluminium allow a better surface finishing
so that the tendency for cold welding is reduced.
Source: Haller
alu
Training in Aluminium Application Technologies
Tool Materials 3705.06.01
TALAT 3705 25
26. Surface Coatings for Drawing Tools
Surface treatments are being increasingly used to improve the wear resistance and to
prevent or reduce the possibility of cold welding as well as to improve the gliding char-
acteristics. In addition to the classical processes of hardening, case hardening, nitriding,
boriding and hard chromium plating, there is an increasing tendency to use hard com-
pound layers based on titanium nitride (TiN) and titanium carbide (TiC). Such layers are
applied using either the chemical vapour deposition (CVD) or the physical vapour depo-
sition (PVD) process, see Figure 3705.06.02. Coatings deposited using the PVD proc-
ess are gaining in popularity, since the process reaction temperature of maximum 550
°C is far below the tempering temperature of the tool steel used.
Surface Treatment Processes
Powder-
Salt bath
Nitriding Gas-
(Nitrocarburising) Plasma-
Reaction
Boriding Powder-
layers
Pastes-
Vanadising
TD process
Ion implanting VD process
Coatings
mainly N
W2C
Applied Hard chromium
TiC
layers plating
TiN
CVD process TiC + TiN
CrxCy
PVD process
TiN
alu
Training in Aluminium Application Technologies
Surface Treatment Processes 3705.06.02
Through the use of coatings, it is possible to utilise the properties of both the protective
coating and the base material. The protective coating increases the wear resistance and
the base material absorbs the mechanical stresses without affecting the coating.
TALAT 3705 26
27. 3705.07 Examples
Figure 3705.07.01: CAD depiction of a coupè door planking
CAD illustration of a coupé door planking
Source: IfU Stuttgart
alu
CAD Illustration of a Coupé Door Planking 3705.07.01
Training in Aluminium Application Technologies
Figure 3705.07.02: Designing surfaces
Designing surfaces
Source: IfU Stuttgart
alu
Designing Surfaces 3705.07.02
Training in Aluminium Application Technologies
TALAT 3705 27
28. Figure 3705.07.03: CAD depiction of edge "B" of the drawing punch surface
CAD illustration of edge ''B''
of the drawing punch surface
Source: IfU Stuttgart
alu
CAD Illustration of edge ''B'' of the Drawing Punch Surface 3705.07.03
Training in Aluminium Application Technologies
Figure 3705.07.04: Considering springback in the design
Considering springback in the design
Source: IfU Stuttgart
alu
Training in Aluminium Application Technologies
Considering Springback in the Design 3705.07.04
The a.m. Figures are all examples of computer assisted designing of body parts.
TALAT 3705 28
29. 3705.08 List of Figures
Figure No. Figure Title (Overhead)
3705.01.01 Forecast for the Year 2000
3705.02.01 Influence of Cold Work and Simulated Lacquer Stoving on Yield
Strength
3705.02.02 Effect of r-Value on Yield Locus
3705.02.03 Elongation Values for AlMgSi1-ka in Polar Coordinates
3705.02.04 Vertical Anisotropy r for AlMg5Mn-w as a Function of Rolling Direction
3705.03.01 Stretch Forming
3705.03.02 Mechanical Drawing
3705.03.03 Strain-Path Curves for Mechanical Drawing
3705.03.04 Hydraulic Drawing
3705.03.05 Strain-Path Curves for Hydraulic Drawing
3705.03.06 Comparison of the Principal Strains ϕg for Mechanical and Hydraulic
Drawing
3705.03.07 Deep Drawing with a Hemispherical Punch
3705.03.08 Deep Drawing and Stretch Forming
3705.03.09 Drawing Irregular Sheet Shapes of Large Areas
3705.04.01 Control of Material Flow under Blankholder
3705.04.02 Arrangement of Draw Beads
3705.05.01 Drawing Equipment
3705.05.02 Four-Point Drawing Equipment
3705.05.03 Desired and Actual Curves for Blankholder Force
3705.05.04 Advantages of a Servo Hydraulic Die Cushion in the Press Table
3705.05.05 Four-Point Die Cushion in the Press Table
3705.05.06 Four-Point Die Cushion in a Press Table with Adjustable Spindle Sleeves
3705.05.07 Functional Principle of a Spindle Sleeve Adjustment
3705.05.08 Experimental Construction of a Simple Acting Hydraulic Press (10-
Point))
3705.05.09 Blankholder and Spindle Sleeve Forces
3705.05.10 Force-Stroke Curves
3705.05.11 A Hydraulic 4,000 kN Sheet Forming Press
3705.05.12 Four-Point Die Cushion in the Press Table of a Simple Acting Press
3705.05.13 Lower Drawing Frame (I))
3705.05.14 Lower Drawing Frame (II)
3705.05.15 Optimal Working Range for Deep Drawing
3705.06.01 Tool Materials
TALAT 3705 29
30. Figure No. Figure Title (Overhead)
3705.06.02 Surface Treatment Processes
3705.07.01 CAD Illustration of a Coupè Door Planking
3705.07.02 Designing Surfaces
3705.07.03 CAD Illustration of Edge "B" of the Drawing Punch Surface
3705.07.04 Considering Springback in the Design
TALAT 3705 30