Page 17 - MetalForming November 2019

Tooling by Design
areas commonly seen in automotive vehicle parts such as body-side outers, door inners and lift gates. Aleris, an aluminum sheet producer, is working to determine how the blanking process affects the edge formability of an expanding hole in aluminum sheet. In this study, aluminum blanks (5XXX and 6XXX alloys) with a cutout in the center are formed over a large flat top punch. The cutouts, produced using machin- ing, laser cutting and shearing at dif- ferent clearances are formed until edge fracture occurs. Edge strains and form- ing depth between the edge conditions and alloys are compared to see how the blanking method could affect formability of these alloys. The goal: Provide a tool to help predict edge stretch failures in commercial stamp- ing-simulation software.
Another lightweighting issue that confronts metal stampers is the joining of multi-layer dissimilar materials with a single weld from a combination of materials: steel, aluminum, brass, mag- nesium, and cast or sintered metals. One promising solution: friction stir welding, created between workpieces in relative motion to each other. Fric- tion creates heat, leading to a plastic (non-melting) state at the interface joint, with workpieces forged together. With this highly efficient method, about 95 percent of mechanical energy trans- fers as heat into the workpiece, where shielding gasses and filler materials typically are not needed. Imperfect welds also can be captured in real-time and reported across the entire process, allowing for quick adoption of process improvements.
The persons and technologies mentioned here are just a sampling of new, emerging and maturing tech- nologies being presented and dis- played at PMA’s Metal Stamping and Tool & Die Conference, January 28- 29, 2020 in Nashville, TN. For more information or to register for the event, visit www.pma.org/mstd-con- ference/ or contact Marianne Sichi at msichi@pma.org. MF
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