On the Role of Binder Shape for Metal Stampings

The effect of binder shape on the formability of metal stampings is addressed in this work. The paper starts with a discussion of a binder development approach for developable or near developable binders. An FEM based test for closeness to developable surfaces is also presented. In this case, the binder surface is meshed using standard FEM discretization techniques. The test is used as an evaluator for the proneness of wrinkle formation at the binder closing stage under the binder surface. The formability of a door outer panel is evaluated and the forming severity related to binder shape. It is shown that addendum and binder designs are key process variables that have to be designed up front and related to product characteristics.