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George 6. Murshdl Spuce Flight Center, Hzlntsuille, Aldbdmd TECHNICAL MEMORANDUM X-53569

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George 6. Murshdl Spuce Flight Center, Hzlntsuille, Aldbdmd TECHNICAL MEMORANDUM X-53569 NASA TECHNICAL N.4S.4 TM X-53569 MEMORANDUM October 21, 1966 ~ I I: (ACCESSION NUMBER) DEFORMATION PROCESSING OF STAINLESS STEEL by D. E. STROHECKER, A. F. GER;DS, H. J. HENNING and F. W. BOULGER Manufacturing Engineering Laboratory NASA George 6. Murshdl Spuce Flight Center, Hzlntsuille, Aldbdmd TECHNICAL MEMORANDUM X-53569 DEFORMATION PROCESSING OF STAINLESS STEEL D. E. Strohecker, A. F. Gerds, H. J. Henning, and F. W. Boulgersk ABSTRACT This report covers the state of the art of both primary and secondary fabrication methods for stainless steel. Methods currently employed for primary fabrication of these alloys include: rolling, extrusion, forging, and drawing of tube, rod, and wire. Secondary metalworking operations are those processes that produce finished or semifinished parts of sheet, bar, or tubing using additional metalforming operations, The following secondary forming processes are discussed: brake bending, deep drawing, spinning, shear forming, drop hammer, trapped rubber, stretch forming, roll forming, dimpling, joggling, and sizing. Equipment and tooling used for the various operations are discussed and illustrated wherever possible. +;Principal Investigators, Battelle Memorial Institute i Contract No. DA-Ol-O21-~~C-l165i(Z) ! NASA-GEORGE C. MARSHALL SPACE -FLIGHT CENTER NASA-GEORGE C. MARSHALL SPACE FLIGHT CENTER TECHNICAL MEMORANDUM X-53569 DEFORMATION PROCESSING OF STAINLESS STEEL BY D. E. Strohecker, A. F. Gerds, H. J. Henning and F. W. Boulger Prepared for Manufacturing Engineering Laboratory ID Cooperation with Technology Utilization Office Under the Supervision of Reds tone Scientific Infonnation Center U. S. Army Missile Command Redstone Arsenal, Alabama MSFC Order No. H-76715 Report No. RSIC-602 Subcontracted to Battelle Memorial Institute 505 King Avenue Columbus, Ohio Contract No. DA-01-021-A~C-11651(Z) PREFACE This report is one of series of state-of-the-art reports being prepared by Battelle Memorial Institute, Columbus, Ohio, under Contract No. DA-01-021-AMC-l1651(Z) in the general field of materials fabrication. This report on practices used to deform the stainless steels into useful shapes is intended to provide information that may be of use to designers and fabricators. Recommendations are considered to be reliable guides for selecting conditions, tools, and equipment for specific operations and the causes for many of the problems encountered are identified and pre- cautions for avoiding them are mentioned. The report summarizes information collected from equipment manufacturers, technical publications, reports on government contracts, and by interviews with engineers employed by major stainless steel fabrication companies in the United States. A total of 134 references are included, most of which cover the period since 1960. ii TABLE OF CONTENTS Page SUMMARY .......................................... 1 INTRODUCTION....................................... 3 Austenitic Stainless Steels ........................... 5 Ferritic Stainless Steels ............................ 7 Martensitic Stainless Steels .......................... 8 PRIMARY DEFORMATION PROCESSES ....................... 11 Rolling ........................................ 13 Rolling Equipment .............................. 14 Rolling Practices for Stainless Steel .................. 19 Sizes and Tolerances of Rolled Products ............... 21 Future Rolling Capabilities ........................ 28 Extrusion ...................................... 30 Classification of Extrusion Processes ................. 31 Extrusion Equipment and Tooling .................... 35 Extrusion Practices ............................. 37 Extrusion Forces ............................... 40 Availability of Stainless Steel Extrusions ............... 41 Extrusion Developments .......................... 42 Forging ....................................... 47 Classification of Forging Processes .................. 48 ForgingEquipment .............................. 48 Forging Practices for Stainless Steels ................. 57 ForgingDesign ................................ 59 Future Developments in Forging ..................... 59 Drawing ....................................... 62 Rod and Wire Drawing.............................. 63 Cleaning of Wire ............................... 63 Coatings ..................................... 65 Equipment .................................... 65 Pointing ..................................... 67 DrawingDies.................................. 70 Lubricants for Wire Drawing ....................... 70 Available Forms ............................... 75 iii TABLE OF CONTENTS (Continued) Page TubeDrawing ................................... 76 Available Tube Sizes............................. 81 SECONDARY DEFORMATION PROCESSES ..................... 83 Brake Bending ................................... 89 Introduction ................................... 89 Principles of Bending ............................ 89 Presses Used for Brake Bending ..................... 92 Tooling ...................................... 92 Bending Procedures ............................. 97 Bending Limits ................................ 101 Springback ................................... 105 Post-Forming Operations ......................... 105 Deep Drawing ................................... 107 Introduction ................................... 107 Presses for Deep Drawing ......................... 107 Tooling for Deep Drawing ......................... 109 Techniques for Deep Drawing ....................... 116 Lubricants ................................... 119 Developments of Blanks ........................... 121 Principles of Deep Drawing ........................ 121 Deep-Drawing Limits ............................ 126 Spinning ....................................... 130 Introduction ................................... 130 Principles of Spinning ............................ 130 Equipment.................................... 133 Tooling...................................... 133 Lubricants ................................... 134 Blank Preparation .............................. 134 Spinning Limits ................................ 135 Examples of Spun Parts ........................... 135 Shear Forming................................... 144 Introduction ................................... 144 Principles of Shear Forming ....................... 144 iv TABLE OF CONTENTS (Continued) Page Cone Shear Forming ............................. 144 Tube Shear Forming ............................. 148 Equipment .................................... 149 Tooling ...................................... 155 Lubricants ................................... 155 Blank Preparation .............................. 157 Blank Development .............................. 157 Shear Forming Limits............................ 159 Properties After Shear Forming ..................... 159 Flexible Die Forming .............................. 168 Introduction ................................... 168 Presses ..................................... 171 Tooling ...................................... 173 Techniques for Flexible Die Forming.................. 175 Blank Preparation .............................. 178 Forming Limits ................................ 179 Sample of Parts Formed in Flexible Dies ............... 182 Drop-Hammer Forming............................. 193 Introduction ................................... 193 Drop-Hammer Presses ........................... 193 Tooling...................................... 194 Techniques of Drop-Hammer Forming .................197 Lubricants ................................... 201 Blank Preparation .............................. 201 Forming Limits ................................ 202 Examples of Drop-Hammer Formed Parts .............. 205 Stretch Forming.................................. 209 . Introduction ................................... 209 Tooling...................................... 213 Techniques of Stretch Forming ...................... 216 Blank Preparation .............................. 217 Stretch Forming Limits ........................... 218 Examples of Stretched Formed Parts ..................232 V TABLE OF CONTENTS (Continued) Page Roll Forming and Roll Bending ....................... 237 Introduction .................................. 237 Roll Forming................................. 239 Roll Bending ................................. 245 Equipment................................... 246 Tube Forming .................................. 259 Tube Bending................................. 259 Equipment ................................... 263 Tube Bulging ................................. 269 Tooling ..................................... 275 Example of Bulge Formed Parts .................... 279 Joggling ...................................... 285 Introduction .................................. 285 Tooling..................................... 286 Material Preparation ........................... 287 Lubricants .................................. 287 Joggling Limits ............................... 287 Dimpling...................................... 293 Introduction .................................. 293 Radius Dimpling............................... 293 Coin Dimpling ................................ 295 Principles of Ram-Coin Dimpling ................... 297 Equipment ................................... 299 Tooling ..................................... 302 Lubricants .................................. 302 Calculated Dimpling Limits ......................
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