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R&D Update: Design rules for forming aluminum stampings—Part 2

Addendum design methods for aluminum stampings
STAMPING JOURNAL JULY/AUGUST 2001 (/PUBLICATION/SJ/JULY-AUGUST-2001)
FEBRUARY 2, 2002
BY: TAYLAN ALTAN, PH.D. (/AUTHOR/TAYLAN-ALTAN)

Editor's Note: This column was prepared by the staff of the Engineering Research
Center for Net Shape Manufacturing (ERC/ NSM), The Ohio State University,
Professor Taylan Altan, director. It is the second of a two-part series on the topic
of stamping of aluminum alloys. The first part was published in the May/June
issue and discussed part design considerations and practical part and tooling
design rules. This issue's article covers addendum design methodology for
improving the formability of aluminum stampings.

Addendum types are additional die features that enable or improve the stamping
of a sheet metal part. They usually are located inside the punch opening line (die
contour) but outside of the trimming line (seeFigure 1). They are removed by the
trimming operation.

Addendums serve three purposes: (https://static.thefabricator.com/a/design-rules-for-forming-

aluminum-stampings-part-2-0.jpg?size=1000x1000)
1. They are necessary for their transition features depending on the chosen blank

Figure 1:
Addendum types enable or improve the stamping of a sheet metal part. A draw wall, for example, connects the trim line and the punch opening line.
holder design.

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2. They help prevent wrinkling and tearing.

3. They facilitate subsequent process steps, such as flanging.

Addendum types should be used only when absolutely necessary. The decision to use them is made by the designers and the tryout experts, who
usually base their decision on experience.

Commonly used addendum types are draw walls, drawbars, stretch walls, gainers, pillows, and bubbles. Draw walls and drawbars are the types
most commonly chosen by die designers.

Draw Walls
A draw wall is a straight connection from
the edge of the part to the punch
opening line on the blank holder
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17.05.2018 R&D Update: Design rules for forming aluminum stampings—Part 2 - The Fabricator
(seeFigure 1). The varying parameters
are the length, angle, and radii used at
both ends.

Draw walls are used to match height

differences between the blank holder
surface and the product surface (see
Figure 2). They also are used to control
the amount of metal drawn into the
cavity by varying the length and the
angle.

The draw wall's punch radius should be Figure 2:

about 20 Draw walls are used to match height differences between the blank holder surface and the product surface.
millimeters for
aluminum
stampings (see
Figure 3). This
large radius
helps to
distribute the
strains more
equally,
whereas a
smaller radius
leads to a strain Figure 3:
concentration Draw beads have to be located 16 to 20 mm apart from the die radius. This large radius helps to distribute the strains more equally.
near the die corner, which may cause failure. The same conditions apply to the die radius. A die radius of 10 millimeters usually is sufficient for
aluminum stampings.

The minimum angle that should be used for a draw wall is 6 degrees. This angle should increase as the draw depth increases to prevent severe
forming conditions. If the amount of drawing into the die cavity is not large, then a larger angle can be used to design the draw wall. If the design
requires draw beads, they will be most effective if placed 16 to 20 millimeters away from the die radius (see Figure 3).

Drawbars
Drawbars (see Figure 4) look like exaggerated draw beads. The male bar usually is part of the punch, and the female bar is in the die. Drawbars
are used to eliminate wrinkling by compensating for the excess metal caused by the differences in draw depth.

A punch radius of nine to 12

times the sheet thickness
along the straight sides and
a minimum radius of 12
times the sheet thickness in
the corners are suggested.
The die radius should be
nine times the sheet Figure 4:
thickness along the straight Drawbars look like exaggerated draw beads. The male bar usually is part of the punch, and the female bar is in the die.
sides and nine to 12 times
the sheet thickness in the corners. The drawbar radius should be a minimum of 20 millimeters.

A distance of 16 to 20 millimeters from the draw bead usually is sufficient for aluminum stampings. The dimensions in Figure 4are given for
aluminum sheet metal with a thickness of 1 millimeter.

A basic consideration in the tryout stage is to lower the depth or increase the radius of the drawbar if tearing occurs. Wrinkling is eliminated by
increasing the depth or decreasing the radius. Also, the depth of the drawbars may influence the trim line considerations.Sometimes the depth of
the drawbar has to be increased to provide enough space for the trimming tool. The trimming line should not be on a radius but on a straight
surface. Therefore, any addendum radius should start about 6 millimeters below the trimming line (see Figure 5).

Figure 5:
Sometimes the depth of the drawbar has to be increased to provide enough space for the trimming tool. The trimming line should not be on a radius
but on a straight surface. Therefore, any addendum radius should start about 6 mm below the trimming line.
Taylan Altan is a professor and director of the Engineering Research Center for Net Shape Manufacturing, 339 Baker Systems, 1971 Neil Ave.,
Columbus, OH 43210-1271, phone 614-292-9267, fax 614-292-7219, Web site nsmwww.eng.ohio-state.edu (http://nsmwww.eng.ohio-state.edu).
The ERC/NSM conducts research and development; educates students; and organizes workshops, tutorials, and conferences for the industry in
stamping, tube hydroforming, forging, and machining.

Reference
https://www.thefabricator.com/article/stamping/design-rules-for-forming-aluminum-stampings-part-2 2/6
17.05.2018 R&D Update: Design rules for forming aluminum stampings—Part 2 - The Fabricator
T. Burk, "Addendum Design Methodology and Tool Design for Aluminum Sheet Metal Forming," Diploma Thesis, Metal Forming Institute, University
of Stuttgart, Germany, 1994.

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Taylan Altan, Ph.D.

Professor Emeritus and Director - Center for Precision Forming
The Ohio State University
1971 Neil Ave.
Columbus, OH 43210
Phone: 614-292-5063

https://www.cpf.osu.edu (https://www.cpf.osu.edu)
Contact via email (mailto:altan.1@osu.edu)

More Content by Taylan Altan, Ph.D. (/author/taylan-altan)

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