International Deep Drawing Research Group

Last updated April 09, 2019

International Deep Drawing Research Group (IDDRG)

Background

The International Deep Drawing Research Group (IDDRG) focuses on sheet metal research in industry and academia. It was started 1957 as an organization of national groups.^[1] The original focus was on the fabrication of cups hence the name Deep Drawing Research Group. At the initial meeting the purpose was enlarged to do cooperative research on tests, materials, and processes. Such work included for example, methods for determining the strain hardening exponent n, the anisotropy-values (lankford coefficient), as well as other tests for sheet metal formability and, later, forming limit diagrams.^[2]

Sheet metal is metal formed by an industrial process into thin, flat pieces. Sheet metal is one of the fundamental forms used in metalworking and it can be cut and bent into a variety of shapes. Countless everyday objects are fabricated from sheet metal. Thicknesses can vary significantly; extremely thin sheets are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate steel or "structural steel."

The strain hardening exponent, noted as n, is a material's constant which is used in calculations for stress–strain behavior in work hardening. It occurs in the formula known as Hollomons equation after John Herbert Hollomon Jr. who originally proposed it:

The Lankford coefficient is a measure of the plastic anisotropy of a rolled sheet metal. This scalar quantity is used extensively as an indicator of the formability of recrystallized low-carbon steel sheets.

Starting in 1960, a schedule was established for working group meetings every year with open Congresses in every second, even numbered years. The working group meetings were closed sessions made up of delegations from the National Groups that comprised the IDDRG. The reason for these closed sessions was to allow experts to informally review critical issues related to materials, tests, and processes.

As some of the initial technical issues were resolved, the working groups became progressively more informal, and over the years became mini conferences. By 1998, it had become obvious that the former format of the IDDRG has to be changed. This evolution took time, but starting in 2003, the meeting schedule shifted to yearly Conferences with both regular papers and poster presentations that are included in conference proceedings.

Mission

The Mission of the International Deep Drawing Research Group (IDDRG) is to co-ordinate research and development work in sheet metal forming, to bring together scientists, researchers and industrialists working on these fields all over the World, to provide open and scientifically highly acknowledged forum to its members to present their research and development findings on all aspects of sheet metal forming and certain related subjects.

The combination of technical presentations and opportunities for discussion are meant to stimulate thinking and to provide valuable interchange of ideas.

Activities

Conferences are normally scheduled for May or June in Europe, North America or Asia. However, most conferences are held in Europe because the majority of the current membership resides in Europe. Conferences start with an informal reception on Sunday evening followed by two and a half days of technical sessions. Ample time is allowed for technical discussion, and various social events are scheduled in association with the conference. Typical topics include machinery and press tools, new processes, new materials, experimental methods for evaluating formability and studying press operations, springback, constitutive equations, plasticity criteria, and friction and wear with attention to interface behavior as characterized by topography and surface chemistry, lubrication, speed, and temperature.

Formability is the ability of a given metal workpiece to undergo plastic deformation without being damaged. The plastic deformation capacity of metallic materials, however, is limited to a certain extent, at which point, the material could experience tearing or fracture (breakage).

In physics and materials science, plasticity describes the deformation of a (solid) material undergoing non-reversible changes of shape in response to applied forces. For example, a solid piece of metal being bent or pounded into a new shape displays plasticity as permanent changes occur within the material itself. In engineering, the transition from elastic behavior to plastic behavior is called yield.

Friction is the force resisting the relative motion of solid surfaces, fluid layers, and material elements sliding against each other. There are several types of friction:

Organization

The officers of the IDDRG are the current President, Vice-Presidents, General Secretary, Treasurer, and active Past-Presidents. The officers of the IDDRG comprise the Executive Committee. The vice-presidents are selected for their expertise and to represent, as far as possible, the geographic distribution of the member countries. Specific responsibilities of vice-presidents are to contact and represent the National delegations in their geographic area and to chair technical sessions at conferences.

Member Countries

Member countries include: Australia, Austria, Belgium, Brazil, Canada, Czech Republic, China, Denmark, Finland, France, Germany, Hungary, Italy, Japan, Luxembourg, Netherlands, Norway, Portugal, Slovakia, Slovenia, South Korea, Spain, Sweden, Switzerland, and the United States.

Australia, officially the Commonwealth of Australia, is a sovereign country comprising the mainland of the Australian continent, the island of Tasmania and numerous smaller islands. It is the largest country in Oceania and the world's sixth-largest country by total area. The neighbouring countries are Papua New Guinea, Indonesia and East Timor to the north; the Solomon Islands and Vanuatu to the north-east; and New Zealand to the south-east. The population of 25 million is highly urbanised and heavily concentrated on the eastern seaboard. Australia's capital is Canberra, and its largest city is Sydney. The country's other major metropolitan areas are Melbourne, Brisbane, Perth and Adelaide.

Austria, officially the Republic of Austria, is a country in Central Europe comprising 9 federated states. Its capital, largest city and one of nine states is Vienna. Austria has an area of 83,879 km² (32,386 sq mi), a population of nearly 9 million people and a nominal GDP of $477 billion. It is bordered by the Czech Republic and Germany to the north, Hungary and Slovakia to the east, Slovenia and Italy to the south, and Switzerland and Liechtenstein to the west. The terrain is highly mountainous, lying within the Alps; only 32% of the country is below 500 m (1,640 ft), and its highest point is 3,798 m (12,461 ft). The majority of the population speaks local Bavarian dialects as their native language, and German in its standard form is the country's official language. Other regional languages are Hungarian, Burgenland Croatian, and Slovene.

Belgium, officially the Kingdom of Belgium, is a country in Western Europe. It is bordered by the Netherlands to the north, Germany to the east, Luxembourg to the southeast, France to the southwest, and the North Sea to the northwest. It covers an area of 30,688 square kilometres (11,849 sq mi) and has a population of more than 11.4 million. The capital and largest city is Brussels; other major cities are Antwerp, Ghent, Charleroi and Liège.

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Hydroforming is a cost-effective way of shaping ductile metals such as aluminium, brass, low alloy steel, and stainless steel into lightweight, structurally stiff and strong pieces. One of the largest applications of hydroforming is the automotive industry, which makes use of the complex shapes made possible by hydroforming to produce stronger, lighter, and more rigid unibody structures for vehicles. This technique is particularly popular with the high-end sports car industry and is also frequently employed in the shaping of aluminium tubes for bicycle frames.

Stamping is the process of placing flat sheet metal in either blank or coil form into a stamping press where a tool and die surface forms the metal into a net shape. Stamping includes a variety of sheet-metal forming manufacturing processes, such as punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produces the desired form on the sheet metal part, or could occur through a series of stages. The process is usually carried out on sheet metal, but can also be used on other materials, such as polystyrene. Progressive dies are commonly fed from a coil of steel, coil reel for unwinding of coil to a straightener to level the coil and then into a feeder which advances the material into the press and die at a predetermined feed length. Depending on part complexity, the number of stations in the die can be determined.

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Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. It is thus a shape transformation process with material retention. The process is considered "deep" drawing when the depth of the drawn part exceeds its diameter. This is achieved by redrawing the part through a series of dies. The flange region experiences a radial drawing stress and a tangential compressive stress due to the material retention property. These compressive stresses result in flange wrinkles. Wrinkles can be prevented by using a blank holder, the function of which is to facilitate controlled material flow into the die radius.

Cold working or cold forming is any metalworking process in which metal is shaped below its recrystallization temperature, usually at the ambient temperature. Such processes are contrasted with hot working techniques like hot rolling, forging, welding, etc.

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Shear forming, also referred as shear spinning, is similar to metal spinning. In shear spinning the area of the final piece is approximately equal to that of the flat sheet metal blank. The wall thickness is maintained by controlling the gap between the roller and the mandrel. In shear forming a reduction of the wall thickness occurs.

Rubber pad forming (RPF) is a metalworking process where sheet metal is pressed between a die and a rubber block, made of polyurethane. Under pressure, the rubber and sheet metal are driven into the die and conform to its shape, forming the part. The rubber pads can have a general purpose shape, like a membrane. Alternatively, they can be machined in the shape of die or punch.

A forming limit diagram, also known as a forming limit curve, is used in sheet metal forming for predicting forming behavior of sheet metal. The diagram attempts to provide a graphical description of material failure tests, such as a punched dome test.

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Today the metal forming industry is making increasing use of simulation to evaluate the performing of dies, processes and blanks prior to building try-out tooling. Finite element analysis (FEA) is the most common method of simulating sheet metal forming operations to determine whether a proposed design will produce parts free of defects such as fracture or wrinkling.

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References

↑ Col, A.: “How started IDDRG?” in ‘Tools and Technologies for the Processing of Ultra High Strength Steels´, IDDRG2010 Conference Proceedings, Kolleck, R. (ed.), Verlag der Technischen Universität Graz, 2010, ISBN 978-3-85125-108-1.
↑ Marciniak, Z.; Duncan, J.L.; Hu S.J.: “The Mechanics of Sheet Metal Forming”, 2nd edition, Butterworth-Heinemann, 2002, ISBN 0-7506-5300-0.

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[col-1] Col, A.: “How started IDDRG?” in ‘Tools and Technologies for the Processing of Ultra High Strength Steels´, IDDRG2010 Conference Proceedings, Kolleck, R. (ed.), Verlag der Technischen Universität Graz, 2010, ISBN 978-3-85125-108-1.

[Marc-2] Marciniak, Z.; Duncan, J.L.; Hu S.J.: “The Mechanics of Sheet Metal Forming”, 2nd edition, Butterworth-Heinemann, 2002, ISBN 0-7506-5300-0.