Stamping a 2mm aluminium plate

[drodrig]

Hi there,

We have a 2mm 6060 aluminium plate helping to cool some elements. In order to reach these elements we plan to stamp it where they can be in contact (plate and elements).

How can I know how deep can we stamp it?

We want to go down by 5mm. The stamps are squares with a side of 28mm

Would this be possible?

How much would the plate deform?

Our workshop has a hydraulic press. We could make a steel mould to shape the aluminium

cheers,

 

[EdStainless]

Try reading up

https://ercnsm.osu.edu/sites/ercnsm.osu.edu/files/uploads/S_coldwarmforming/642_12.pdf

https://ercnsm.osu.edu/sites/default/files/uploads/642-13.pdf

https://www.intechopen.com/books/al...sites/aluminum-alloys-behavior-during-forming

You will need to think about alloy, HT condition, forming shape (more radius), and lubrication.

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P.E. Metallurgy, consulting work welcomed

 

[3DDave]

A 6000 series is not what springs to mind for drawing operation. 1000 and 5000 series are, to memory, more formable.

If the quantity is small just mill them out of thicker, stress relieved plate.

 

[Artisi]

Why not just make a simple 1 indent die and run a few trials, however you haven't given any quantity - is it one plate or thousands - that will govern the best method to use.

It is a capital mistake to theorise before one has data. Insensibly one begins to twist facts to suit theories, instead of theories to suit facts. (Sherlock Holmes - A Scandal in Bohemia.)

 

[mfgenggear]

drodrig

the starting material must be in the annealed condition. and have to look at the % of elongation. then work back by calculation the physical change in length. ball park.
forming unfortunately is trial and error. run test pieces and try out forming it. and verify the results. adjust the punch geometry until the it obtains the correct geometry.
there is information out there on the minimum radius and max depth for draw of the material. if it is a deep draw sometimes a takes successive re annealing and re punching the form.
5 mm depth should be a breeze.

 

[hendersdc]

Do the side walls have to be vertical? Having an angle there will make this much easier to form if your application allows it.

Does the material have to be aluminum? Steel would be much easier as well.

 

[drodrig]

Hi there,

I didn't say.

We just need one part. Maximum two.

Milling a plate would be possible, but wouldn't it deform a lot? The maximum thickness is 7mm. We would need to take an 8mm plate and machine it completely from both sides

I read the articles. It seems the 5000 series is more suitable, but they have lower thermal conductivity.

We can make tests making a punch and a die. But first we need to know if what we want to do is possible at all: creating 5mm deep pockets in a 2mm plate

I can't find the recommended radiuses for the drawing process. Does anybody have some data?

thanks
regards,

 

[rb1957]

3t radius, well that's what we use for bend radius.

Do you need a continuous sheet ? What about flanged lightening holes ? That's something we do.

What about perforated sheet ??

another day in paradise, or is paradise one day closer ?

 

[drodrig]

3t is feasible for us

we need a continuous plate. no holes

It is for cooling, so the more material, the better

thanks

 

[rb1957]

you mean you're using it as a heat sink (you get more cooling with openings).

ok, then use steel (not Aluminium)

As a heat sink, you don't really have a structural requirement, a minimum thickness (so stretching/thinning in the formed sections is ok).

another day in paradise, or is paradise one day closer ?

 

[drodrig]

The idea is using this plate to "bring the cold" to the stamped points (active cooling on the perimeter)

We must use aluminium, not only because its thermal conductivity but also because it has a low atomic number and low radiation length

cheers,

 

[IFRs]

Honestly, just try one, if it works you've got 50% of your needs!
You don't mention the temper or hardness of the 6060 material, a 5xxx or 3xxx alloy will be less likely to crack and the thermal properties are the same or nearly so.

 

[EdStainless]

Build a simple single punch die, it doesn't need to be hardened.
Get a sheet of annealed 1xxx Al and go to it.
If you get some overall distortion it will be soft enough to 're-flatten' it afterward.

= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, consulting work welcomed

 

[drodrig]

ok!
we will start making some tests

thanks everybody

 

[Rex Hang]

Aluminum sheet and aluminum plate are the most widely used forms of aluminum and can be applied to a variety of applications. You can take help from HeatSign.