Research shows that in forming lightweight materials such as aluminum and magnesium alloys, the formability increases as the temperature increases, especially in the range from 200 degrees C to 300 degrees C (392 degrees F to 572 degrees F).1-5 The Center for Precision Forming (CPF, formerly...
The ERC/NSM conducted experiments using round cup tooling to determine the influence of temperature on the limiting draw ratio – the largest draw ratio of the blank-to-cup diameter that can be drawn successfully.
To prevent martensitic transformation in stainless steel during drawing operations, warm forming has been explored. In experiments, warm forming eliminated intermediate annealing operations and substantially increased limiting draw ratio values.
November 8, 2005 | By Taylan Altan, Ph.D.
In recent studies, dry-film lubricants have been shown to give better lubrication conditions when compared to oil-based liquid lubricants. This factor, as well as savings in the amount of lubricant used, has helped increase the use of dry-film lubricants in the automotive industry for forming of aluminum and high-strength steel stamped parts
August 9, 2005 | By Taylan Altan, Ph.D.
Reducing weight while maintaining or improving functional requirements is one of the major goals of automotive design and manufacturing, as it decreases fuel consumption and improves structural design. As a result of these considerations, the use of aluminum alloys in car manufacturing continues to increase, not only in body panels but also in structural, power train, and suspension components.
Hydroforming often results in localized thinning. Using engineered tubes—tubes that have a thicker wall where the tube is most prone to thinning—can result in a stronger finished component.
Roll forming is a common method for producing steel tubes. It is a continuous process in which a strip is guided through several sets of rolls that form the strip into the desired shape. After the final shape is achieved, tube edges are welded together to form a closed section. After the welding operation, the tube is sized through another set of rolls to obtain the required diameter.
October 9, 2003 | By Taylan Altan, Ph.D.
Editor's Note: This column was prepared by the staff of the Engineering Research Center for Net Shape Manufacturing (ERC/ NSM), The Ohio State University, Professor Taylan Altan, director.Air bending and straight flanging are the most prevalent types of bending in sheet metal forming. Predicting...
August 28, 2003 | By Taylan Altan, Ph.D.
Editor's Note: This column was prepared by the staff of the Engineering Research Center for Net Shape Manufacturing (ERC/ NSM), The Ohio State University, Professor Taylan Altan, director.Binder, or blank holder, force control is an important variable in the stamping process. Constant blank holder...
June 12, 2003 | By Taylan Altan, Ph.D.
Dieless NC forming or incremental sheet forming is a numerically controlled incremental process that can produce complex shapes from various materials. The process is based on localized plastic deformation in the sheet metal blank. It was developed as an alternative manufacturing method to prototype sheet metal stampings and produce panels in small lot sizes.
April 15, 2002 | By Taylan Altan, Ph.D.
Sheet hydroforming can be used in the automotive industry for forming alloys with low formability and prototype applications, among other handy applications.
February 2, 2002 | By Taylan Altan, Ph.D.
This brief overview discusses rules for aluminum stamping involving: die clearance, die radius, punch radius, minimum bend radii, round cups, rectangular box parts, and overhang limit.
February 2, 2002 | By Taylan Altan, Ph.D.
Figure 1:Addendum types enable or improve the stamping of a sheet metal part. A draw wall, for example, connects the trim line and the punch opening line.Editor's Note: This column was prepared by the staff of the Engineering Research Center for Net Shape Manufacturing (ERC/ NSM), The Ohio State...
October 11, 2001 | By Taylan Altan, Ph.D.
Strain hardening is represented by the exponent n in the flow stress equation, which approximates the relation between true stress and true strain during plastic deformation of a metal. The constant n plays a crucial role in sheet metal forming, and this brief article describes its effects.
A typical tube hydroforming system is shown in Figure 1. Within this system, a host of factors must be taken into account, from starting tube geometry and material properties to the quality of the final part (such as thickness distribution and dimensional accuracy).