Formability

Topics

Concept of formability

Formability of materials:

bulk forming

Sheet forming

Measurement techniques
 Concept of formability

The plastic deformation is limited by:

- plastic instability
- crack and fracture

Instable plastic deformation:

In a certain point of the material the effect of
hardening is abrogated by the softening.

The source of softening can be:

change of geometry,
change of the strain rate
change of temperature.
 Plastic instability

The plastic deformation of stable if the force

increases with increasing deformation
> 0
Tension of cylindrical specimen
= 0
Load: =

Limit of stability: = = + = 0

=
=
 Plastic instability

Assuming that = =

The limit of stability: =

Plastic instability occurs what the critical strain is

reached; it leads to local plastic deformation
(contraction) and fracture of the sample

Plastic instability can occur at forming of sheats of

car bodies; as local thinning of the sheet.

It is benefitial if the value of n is higer.

 Plastic strain to fracture

The limit of the deformation. The formability of the

material decreases during the forming process. If
the strain reaches the a critical value ( -
plastic strain to fracture) fracture occurs.

The limit of the deformation depends on the

temperature, the strain rate and on the local stress
state. It can be characterized by two quantities:
Lode parameter ( )
Mayers stress state (k)
 Formability diagram

The occurrence of a fracture can be analyzed by

the forming limit diagrams:
fracture f k

The forming limit diagram of bulk forming processes

can be determined by conducting experiments
causing different stress states (tensile, upsetting,
torsion, bending etc. test)
The increasing of the temperature shifts the curves
upwards
The increasing of the strain rate shifts the curves
downwards
 Formability diagram

t a2 a1 a2 exp b2 b1 b2 k
fracture

t
fracture = .
Plastic strain to fracture

= .

= -1
= 0

- Mayers stress state - k +

 Bogatov theory

1 1
= =


0 =1 0

= (, , , , ) = (, , , , )

1 + 2 + 3 22 1 3
= =
1 3

= 1 fracture
 Forming limit diagram (FLD)

The formability is characterized by the forming limit

diagram (FLD) for sheet forming techniques

1 Fracture can
be expected

Safe
zone

0 + 2
 Forming limit diagram (FLD)

Determination of the FLD using Nakazima test

1 1

2
 R and n values

Important quantities of sheet formability:

Lankford coefficient(R)
hardening exponent (n).
The R value characterizes the normal anisotropy
(perpendicular to the sheets plane) of the sheet.
b Cross section
ln of the tensile
d v v b0 test specimen
R
d w w s so
ln
s0 bo
bo and so are the original, b and s the deformed dimensions.
The is the angle describing the specimens orientation relative
to the rolling direction of the sheet.
 R and n values

The Lankford coefficient is the weighted average of

the R values measured in the directions 0, 45 and
90
R0 2 R45 R90
R (normal anisotropy)
4

From the R values the planar anisotropy of the

sheet can be calculated:

R0 R90
R R45 (planar anisotropy)
2
 R and n values

The hardening exponent is the exponent of the flow

curve which is also direction dependent:

c n

the weighted average of the n values measured in

the directions 0, 45 and 90
n0 2n45 n90
n
4
From the n values the planar anisotropy of the
sheet can be calculated:
n0 n90
n n45
2
The connection of R and n values to deep drawing

Stress and strain state during deep drawing

in the cylinder

in the flange
 The connection of R and n values
to sheet forming technologies

St DD
Hardening exponent

St

DD

DD good for deep drawing Lankford coefficient

St good for stretch forming
 R and n values for some materials

Jel C n R
N/mm C
K nn R
Carbon steel 0 554,7 0,1714 1,817

Carbon steel 45 584 0,1619 1,067 552,8 0,164 1,59

Carbon steel 90 488,6 0,1454 2,41

AlMg3 0 461.6 0.2914 0.613

AlMg3 45 362.75 0.2647 1.05 405.4 0.2936 0.9675

AlMg3 90 434.4 0.2937 1.157

 Technological tests - Erichsen test

punch
sphere blank holder

specimen

die

quantity: displacement of the punch from the contact till the

crack of the specimen (mm)
 Technological tests deep drawing of a cup

3 types of punch

blank holder
Quantity:
d1
m
die Dmax
blank

Starting from Do = 58 mm blank diameter, by 2 mm steps till facture (up

to max. 74 mm).
 Technological tests bending

180 degrees crack

Quantity : bending angle till cracking