Sheet Metal Forming

Index / 355
polytetrafluoroethylene (PTFE), 92
Porsche Engineering, 175–176
portable infrared analyzer, 315(F)
pot pressure
room-temperature sheet hydroforming, 158
sheet bulging, 165
SHF-D, 158, 160
SHF-P, 60, 160, 162, 168, 170, 171(F)
prebulging, 160–161, 162
precision blanking. 
See
fine blanking
pre-coated materials, 220
prepainted sheets, 220
press bending, 187, 188(F)
press brake bending
clamping, 45
crowning system, 46
fabrication industry, 42
press bakes, 42
tonnage, 42, 44
tooling, 45, 46(F)
press brake drive types
alternating current (ac)-servo press brake, 44
drive types, 43–44
hydraulic press, 42–43(F), 44(F)
hydromechanical-servo drive, 43–44
mechanical press brake, 42
press brakes, 42
press joining. 
See
clinching
pressure die, 187, 189
pressure pot, 158, 165
pressure vessels/containers, 37
process simulation
advantages, 51
commercial codes, forming simulations
FEA steps, 51–52
FEM, 51
overview, 51
commercial software, 52(T)
commercial software, code features
dynamic explicit, 52
inverse (one-step) approach, 52
quasi-static implicit approach, 52
FEM simulations (
see
finite-element method (FEM) 
simulations)
objectives, 51
overview, 51
process window, 167–168(F)
production dies, 200(F)
profile roll forming, 217
progressive die design, 74, 77, 81–82. 
See also
progressive 
die forming
progressive die forming
case study I: progressive die design
BHF for first stage, 77
design parameters, flow chart, 76(F)
die corner radii, 78(T)
die diameter, 77–78(T)
drawing depth, 77–78(T)
existing automotive part, 74(F)
FEA predicted geometry, 75(F)
FEM and experienced-based methods, comparison 
between, 78–79(F), 80(F)
final sequence, 78(F)
maximum thinning at first stage, 77(F)
new part geometry, 75(F)
overview, 74–75
process sequence design, 75–77
punch corner, 78(T)
punch diameter, 77–78(T)
punch diameter and wall thinning in progressive 
forming stages, 76(F)
simulation model, 77(F)
case study II: transfer die forming of clutch hub, 79–81
clutch hub, 81(F)
coin the inside corner after flanging, 81(F)
coin the plate before flanging, 81(F)
current process—flanging and upsetting, 81(F)
three defects, 80(F)
three stages, 80(F)
knowledge-based systems, 74
overview, 73
process design using FEA, 73–79(F,T)
progressive die strip, 73(F)
progressive die sequence, 58–59(F,T), 75, 78(F)
progressive dies
FE simulation of stamping, 58
fine blanking, 13
fixed punch system, 13
progressive die design, 74
proximity sensors, 305
prototyping, 164, 256, 273, 318, 319(F)
prototyping dies, 198–199
Pryer Machine Co., 160
pullout test, 300
pulsating pressure, 194(F)
pulsed power generator (PPG), 230, 233(F), 237, 239
punch
finite element (FE) simulations, 15–16(F)
mechanics of deformation, 91–92(F)
shearing, 14(F)
SHF-P, 165
systems (fine blanking), 13, 14(F)
warm SHF-P, 171
punch (blanking)
blanking force, 2, 3
blanking presses, 10
compressive stress, calculating, 2
contact of, 1(F)
elastic deformation, 1(F)
high-speed stamping, 8
Jektole punch, 8(F)
lubrication, effect on punch wear, 8–9(F)
misalignment, 8
plastic deformation, 1(F)
punch geometries, 4(F), 6
punch life
clearance, 8
punch coatings, 7
punch materials, 7
punch point geometry, 8

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