*3.3.2. Experiment on stamping-forging process of double-cup-shape part with thickened inner wall*

The typical double-cup-shape part with thickened inner wall is shown in Fig.16. It is a rotary part, in which the thickness of the inner wall is larger than that of other region. In order to improve the mechanical properties of the part, material utilization and production efficiency, the stamping-forging hybrid forming process mentioned before was used. As described earlier, the process was divided into three stages: forward drawing, then backward drawing, piercing and flanging, finally upsetting to get the inner wall thickened (shown in Fig. 17).

**Figure 16.** Scheme of double-cup-shape part

Stamping-Forging Processing of Sheet Metal Parts 43

a) Blanking b) Forward drawing c) Powerful backward drawing d) Piercing and flanging e) Thickening by upsetting

42 Metal Forming – Process, Tools, Design

*inner wall* 

(shown in Fig. 17).

**Figure 16.** Scheme of double-cup-shape part

**Figure 15.** Forming load curve (from step 400 to step 600)

*3.3.2. Experiment on stamping-forging process of double-cup-shape part with thickened* 

The typical double-cup-shape part with thickened inner wall is shown in Fig.16. It is a rotary part, in which the thickness of the inner wall is larger than that of other region. In order to improve the mechanical properties of the part, material utilization and production efficiency, the stamping-forging hybrid forming process mentioned before was used. As described earlier, the process was divided into three stages: forward drawing, then backward drawing, piercing and flanging, finally upsetting to get the inner wall thickened

**Figure 17.** Scheme of stamping-forging processing of double-cup-shape part

The mechanical properties of the material are shown in Table 1. The experiment was conducted at a dual-action deep drawing hydraulic press (see Fig. 18), and the sheet metal material was 08AL steel with initial thickness of 2 mm. The nominal pressure of inner slider is 3000 kN and the outer is 2000 kN. The velocity and maximum effective stroke of the inner and outer slider are 10 mm/s and 500 mm, respectively. The nominal pressure of ejector of the hydraulic machine is 1000 kN, while the ejection stroke is 160 mm, and the velocity is 30 mm/s.


**Table 1.** Mechanical properties of the material

The partial view of backward drawing and upsetting die is shown in Fig. 19. Δ is clearance which influences the flow of material in powerful backward drawing between punch-die and the die. If the gap is too much, wrinkling and folding defect may happen more easily. Instead, the resistance force will be increased, which leads to thinning or even rupture of the inner wall in backward drawing process. According to the thickness of the sheet metal is 2 mm, experiments on the gap were conducted more than once until the most satisfied clearance 3.5 mm was obtained. The formed part is shown in Fig. 20.

Stamping-Forging Processing of Sheet Metal Parts 45

**Figure 20.** Section plan of double-cup-shape part by backward drawing

**Figure 21.** Measurement path of wall thickness of part

After powerful backward drawing, material of outer wall flowed into inner wall. The height of outer wall was decreased from 128 mm to 100 mm, while the height of inner wall was increased to 50 mm. Fig. 21 shows the measurement path of wall thickness along radial direction, and Fig. 22 shows the distribution of wall thickness. It can be seen that the wall thickness is not homogeneous along the radial direction, showing characteristics of shock fluctuation obviously. In the flange region from point 1 to point 10, the wall thickness is larger than that of initial blank due to composite effect of hoop pressure stress and tension stress in the radial direction during forward drawing. In the outer wall region from point 10 to point 23, the wall thickness is less than that of initial blank and it goes down from top to bottom. The diameter of the region point 23 to point 26 decreases with round corner of bottom, because this region is mainly suffered from hoop pressure stress resulting in thickening in the thickness. In the bottom region from point 26 to point 35, the wall thickness first decreases and then increases, and the thinnest place is at the center of bottom plane. In the inner wall region from point 35 to point 52, the wall thickness is severely thinned because of large tension stress in the radial direction; the closer near the central

**Figure 18.** Dual-action deep drawing hydraulic press

1- Upper pressure ring 2- Lower pressure ring 3- Blank holder 4- Floated die 5- Punch and die 6- Fixed die 7- Mandrel

**Figure 19.** Partial view of upsetting die

**Figure 20.** Section plan of double-cup-shape part by backward drawing

**Figure 18.** Dual-action deep drawing hydraulic press

1- Upper pressure ring 2- Lower pressure ring 3- Blank holder 4- Floated die 5- Punch and die 6- Fixed die 7- Mandrel

**Figure 19.** Partial view of upsetting die

After powerful backward drawing, material of outer wall flowed into inner wall. The height of outer wall was decreased from 128 mm to 100 mm, while the height of inner wall was increased to 50 mm. Fig. 21 shows the measurement path of wall thickness along radial direction, and Fig. 22 shows the distribution of wall thickness. It can be seen that the wall thickness is not homogeneous along the radial direction, showing characteristics of shock fluctuation obviously. In the flange region from point 1 to point 10, the wall thickness is larger than that of initial blank due to composite effect of hoop pressure stress and tension stress in the radial direction during forward drawing. In the outer wall region from point 10 to point 23, the wall thickness is less than that of initial blank and it goes down from top to bottom. The diameter of the region point 23 to point 26 decreases with round corner of bottom, because this region is mainly suffered from hoop pressure stress resulting in thickening in the thickness. In the bottom region from point 26 to point 35, the wall thickness first decreases and then increases, and the thinnest place is at the center of bottom plane. In the inner wall region from point 35 to point 52, the wall thickness is severely thinned because of large tension stress in the radial direction; the closer near the central

**Figure 21.** Measurement path of wall thickness of part

region, the thinner the wall is; and the thinnest point is the round corner of backward drawing punch. The region from point 52 to point 60 is also mainly suffered from tension stress, thus the entity wall is thinned. But close to the center, away from round corner of backward drawing punch, the blank is subjected to less deformation, so the wall thickness increases slightly compared with that of round corner.

**Figure 22.** Distribution of wall thickness of part

According to the analysis above, thickness of inner wall is still thinned after powerful backward drawing due to various factors, such as stress in different region and friction between tools and material. However, if we do not use powerful backward drawing, the thickness of inner wall will be thinned more severely. Although the thinning of inner wall during backward drawing is not beneficial to the upsetting of this region, the double-cupshape part with the inner wall of 4 mm was made successfully with optimized processing parameters. To avoid folding defect caused by bending of the blank, an upsetting with small gap and rigid support was used. The thickened part compared with non-thickened part is given in Fig. 23.

a) Part with inner wall non-thickened b) Part with inner wall thickened by upsetting

Stamping-Forging Processing of Sheet Metal Parts 47

e) Upsetting

d) Piercing and flanging

λ

*n N ttt* <sup>−</sup> <sup>=</sup> (1)

> , the thickening could not be

<sup>=</sup> *t t* , where *Nt* is

The forming process of the double-cup part is shown in Fig. 24. It is indicated that the double-cup part can be successfully formed by the mentioned stamping-forging hybrid

> c) Powerful backward drawing

The forming process and methods of typically disc-like part with thickened rim thickened

The following calculations in section 4.1. and 4.2. are based on the assumption of plane deformation which the meridian plane of the work-piece keeps planar during forming process. That is, the deformation can be treated as a process of axisymmetric radial

Thickening ratio is also a key factor during the process design of thickening spinning. It is

*<sup>n</sup>* <sup>1</sup> *t* <sup>−</sup> is the thickness of the rim before the *n* time thickening step. The number of forming

the target thickness and 0*t* is the initial thickness. Generally, the recommend value in a

In a multi-step forming, *nt* is decisive to the roller design and success of the process. Assuming the average strain in each forming step is equivalent, there is

> / 0 *nN N n*

where, *N* is the total number of forming steps, *n* is the number of forming step, 1≤*n*≤*N*.

λ

step required for rim thickening depends on the total thickening ratio 0 / *<sup>N</sup>*

obtained in one forming step, a multi-step thickening process will be needed.

*t t* <sup>−</sup> <sup>=</sup> , where *nt* is the thickness of the rim after the *n* time thickening step,

 <sup>≤</sup> . If 1.4 *<sup>n</sup>* λ

processing.

compression.

defined as 1 / *n nn* λ

a) Blanking b)Forward

**Figure 24.** Forming process of the part

by spinning are introduced in this section.

**4.1. Design of multi-step process** 

single thickening for low carbon steel is 1.4 *<sup>n</sup>*

1 0 <sup>1</sup> ln( / ) ... ln( / ) *N N tt t t* <sup>−</sup> = = . So, the *nt* equals to

drawing

**4. Thickening of flange of disc-like parts with spinning** 

The forming process of the double-cup part is shown in Fig. 24. It is indicated that the double-cup part can be successfully formed by the mentioned stamping-forging hybrid processing.

a) Blanking b)Forward

46 Metal Forming – Process, Tools, Design

increases slightly compared with that of round corner.

**Figure 22.** Distribution of wall thickness of part

given in Fig. 23.

region, the thinner the wall is; and the thinnest point is the round corner of backward drawing punch. The region from point 52 to point 60 is also mainly suffered from tension stress, thus the entity wall is thinned. But close to the center, away from round corner of backward drawing punch, the blank is subjected to less deformation, so the wall thickness

According to the analysis above, thickness of inner wall is still thinned after powerful backward drawing due to various factors, such as stress in different region and friction between tools and material. However, if we do not use powerful backward drawing, the thickness of inner wall will be thinned more severely. Although the thinning of inner wall during backward drawing is not beneficial to the upsetting of this region, the double-cupshape part with the inner wall of 4 mm was made successfully with optimized processing parameters. To avoid folding defect caused by bending of the blank, an upsetting with small gap and rigid support was used. The thickened part compared with non-thickened part is

a) Part with inner wall non-thickened b) Part with inner wall thickened by upsetting

**Figure 23.** Comparison of double-cup-shape part before thickening and after thickening

drawing

c) Powerful backward drawing

d) Piercing and flanging

e) Upsetting

**Figure 24.** Forming process of the part
