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1CharacteristicsofStampingandPropertiesofSheetMetalForming1overviewStampingisakindofplasticformingprocessinwhichapartisproducedbymeansoftheplasticformingthematerialundertheactionofadie.Stampingisusuallycarriedoutundercoldstate,soitisalsocalledstamping.Heatstampingisusedonlywhentheblankthicknessisgreaterthan8100mm.Theblankmaterialforstampingisusuallyintheformofsheetorstrip,andthereforeitisalsocalledsheetmetalforming.Somenon-metalsheets(suchasplywood,micasheet,asbestos,leather)canalsobeformedbystamping.Stampingiswidelyusedinvariousfieldsofthemetalworkingindustry,anditplaysacrucialroleintheindustriesformanufacturingautomobiles,instruments,militarypartsandhouseholdelectricalappliances,etc.Theprocess,equipmentanddiearethethreefoundationalproblemsthatneededtobestudiedinstamping.Thecharacteristicsofthesheetmetalformingareasfollows:(1)Highmaterialutilization(2)Capacitytoproducethin-walledpartsofcomplexshape.(3)Goodinterchangeabilitybetweenstampingpartsduetoprecisioninshapeanddimension.(4)Partswithlightweight,high-strengthandfinerigiditycanbeobtained.(5)Highproductivity,easytooperateandtorealizemechanizationandautomatization.Themanufactureofthestampingdieiscostly,andthereforeitonlyfitstomassproduction.Forthemanufactureofproductsinsmallbatchandrichvariety,thesimplestampingdieandthenewequipmentsuchasastampingmachiningcenter,areusuallyadoptedtomeetthemarketdemands.Thematerialsforsheetmetalstampingincludemildsteel,copper,aluminum,magnesiumalloyandhigh-plasticityalloy-steel,etc.Stampingequipmentincludesplateshearpunchingpress.Theformershearsplateinto2stripswithadefinitewidth,whichwouldbepressedlater.Thelatercanbeusedbothinshearingandforming.2CharacteristicsofstampingformingTherearevariousprocessesofstampingformingwithdifferentworkingpatternsandnames.Buttheseprocessesaresimilartoeachotherinplasticdeformation.Therearefollowingconspicuouscharacteristicsinstamping:(1)Theforceperunitareaperpendiculartotheblanksurfaceisnotlargebutisenoughtocausethematerialplasticdeformation.Itismuchlessthantheinnerstressesontheplateplanedirections.Inmostcasesstampingformingcanbetreatedapproximatelyasthatoftheplanestressstatetosimplifyvastlythetheoreticalanalysisandthecalculationoftheprocessparameters.(2)Duetothesmallrelativethickness,theanti-instabilitycapabilityoftheblankisweakundercompressivestress.Asaresult,thestampingprocessisdifficulttoproceedsuccessfullywithoutusingtheanti-instabilitydevice(suchasblankholder).Thereforethevarietiesofthestampingprocessesdominatedbytensilestressaremorethandominatedbycompressivestress.(3)Duringstampingforming,theinnerstressoftheblankisequaltoorsometimeslessthantheyieldstressofthematerial.Inthispoint,thestampingisdifferentfromthebulkforming.Duringstampingforming,theinfluenceofthehydrostaticpressureofthestressstateinthedeformationzonetotheforminglimitandthedeformationresistanceisnotsoimportantastothebulkforming.Insomecircumstances,suchinfluencemaybeneglected.Eveninthecasewhenthisinfluenceshouldbeconsidered,thetreatingmethodisalsodifferentfromthatofbulkforming.(4)Instampingforming,therestrainactionofthedietotheblankisnotseversasinthecaseofthebulkforming(suchasdieforging).Inbulkforming,theconstraintformingisproceededbythediewithexactlythesameshapeofthepart.Whereasinstamping,inmostcases,theblankhasacertaindegreeoffreedom,onlyonesurfaceoftheblankcontactswiththedie.Insomeextracases,suchastheformingoftheblankonthe3deformingzonecontactwiththedie.Thedeformationintheseregionsarecausedandcontrolledbythedieapplyinganexternalforcetoitsadjacentarea.Duetothecharacteristicsofstampingdeformationandmechanicsmentionedabove,thestampingtechniqueisdifferentformthebulkmetalforming:(1)Theimportanceorthestrengthandrigidityofthedieinstampingformingislessthanthatinbulkformingbecausetheblankcanbeformedwithoutapplyinglargepressureperunitareaonitssurface.Instead,thetechniquesofthesimpledieandthepneumaticandhydraulicformingaredeveloped.(2)Duetotheplanestressorsimplestrainstateincomparisonwithbulkforming,moreresearchondeformationorforceandpowerparametershasbeendone.Stampingformingcanbeperformedbymorereasonablescientificmethods.Basedontherealtimemeasurementandanalysisonthesheetmetalpropertiesandstampingparameters,bymeansofcomputerandsomemoderntestingapparatus,researchontheintellectualizedcontrolofstampingprocessisalsoinproceeding.(3)Itisshownthatthereisacloserelationshipbetweenstampingformingandrawmaterial.Theresearchonthepropertiesofthestampingforming,thatis,formingabilityandshapestability,hasbecomeakeypointinstampingtechnologydevelopment,butalsoenhancesthemanufacturingtechniqueofironandsteelindustry,andprovidesareliablefoundationforincreasingsheetmetalquality.3CategoriesofstampingformingManydeformationprocessescanbedonebystamping,thebasicprocessesofthestampingcanbedividedintotwokinds:cuttingandforming.Cuttingisashearingprocessthatonepartoftheblankiscutfromtheother.Itmainlyincludesblanking,punching,trimming,partingandshaving,wherepunchingandblankingarethemostwidelyused.Formingisaprocessthatonepartoftheblankhassomedisplacementfromtheother.Itmainlyincludesdeepdrawing,bending,localforming,bulging,flanging,necking,sizingandspinning.Insubstance,stampingformingissuchthattheplasticdeformationoccursinthe4deformationzoneofthestampingblankcausedbytheexternalforce.Thestressstateanddeformationcharacteristicofthedeformationzonearethebasicfactorstodecidethepropertiesofthestampingforming.Basedonthestressstateanddeformationcharacteristicsofthedeformationzone,theformingmethodscanbedividedintoseveralcategorieswiththesameformingpropertiesandbestudiedsystematically.Thedeformationzoneinalmostalltypesofstampingformingisintheplanestressstate.Usuallythereisnoforceoronlysmallforceappliedontheblanksurface.Whenisassumedthatthestressperpendiculartotheblanksurfaceequalstozero,twoprincipalstressesperpendiculartoeachotherandactontheblanksurfaceproducetheplasticdeformationofthematerial.Duetothesmallthicknessoftheblank,itisassumedapproximatelythetwoprincipalstressesdistributeuniformlyalongthethicknessdirection.Basedonthisanalysis,thestressstateandthedeformationcharacteristicsofthedeformationzoneinallkindsofstampingformingcanbedenotedbythepointsinthecoordinatesoftheplaneprincipalstressesandthecoordinatesofthecorrespondingplaneprincipalstrains.4RawmaterialsforstampingformingTherearealotofrawmaterialsusedinstampingforming,andthepropertiesofthesematerialsmayhavelargedifference.Thestampingformingcanbesucceededo
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