Sheet Metal Testing Machines

These testing machines (type BUP) are used to determine and evaluate sheet metal properties.

Typical test methods include Erichsen cupping tests (EN ISO 20482), in which a hemispherical punch is pressed into a clamped test piece until a crack appears. There is no in-flow of the sheet metal.

The drawing formability of the sheet metal is determined from the punch penetration depth. Another test method frequently used is the earing test to EN 1669. In this test circular blanks are punched or inserted and drawn into cups (metal in-flow). The deep-drawing characteristics of the metal are determined via the percentage ear height ratio.

Other metal-forming test methods include square cup tests, hole expansion tests, FLC tests and bulge tests.

Sheet metal forming test with BUP200, BUP400 and BUP1000 testing machines

Key advantages and features

Description

  • BUP testing machines are available in 5 versions with a maximum ram force of 100, 200, 400, 600 or 1000 kN.
  • A punch function is incorporated into the BUP testing machine, allowing a blank to be pressed and a cup drawn in one operation (from BUP 200 upwards).
  • Individual adjustments to the test sequence are possible, e.g. deep drawing speed and clamping force.
  • With optional testXpert II testing software the test results can also be evaluated graphically and saved .

Advantages & features

  • Fast, easy tool and fixture changes, including drawing-punch, drawing-die, blank-holder, cutting-punch, cutting-ring and scraper-ring. Numerous modular expansion options.
  • Test tools/fixtures from earlier-generation machines can still be used (with some restrictions). Test tools/fixtures for established test methods available 'off-the-shelf', special tools/fixtures on application.
  • Low piston-cylinder friction enables accurate measurement recording and excellent reproducibility.
  • Clean and quiet in operation. Easily transportable thanks to compact design.
  • Hydraulic cup-extractor via integrated piston, with piston rod acting through drawing-punch.
  • Electronics can be swiveled to optimum viewing angle for measured values.
  • Conveniently positioned controls.
  • Electrical and hydraulic protection for all functions.
  • Adjustable automatic blank-holder unloading during test enables cup-drawing without crushing ears.
  • Automatic setting of pre-selected sheet clamping force after blanking procedure.
  • Automatic piston withdrawal and switch-off after end of test due to crack detection or on reaching maximum ram stroke (s-limit).
  • Swing doors and removable casing panels for easy access to components.
  • Change deep drawing speed during test (BUP 400 / 600 / 1000).
  • Operating-mode switch for automatic or manual operation (BUP 400 / 600 / 1000).
  • Hydraulic opening and closing of tool head, with 2-handed operation (BUP 400 / 600 / 1000).
  • Setup stroke for easy tool/fixture change (BUP 400 / 600 / 1000).

Video

Technical overview

100 kN / 200 kN

Type

BUP 100

BUP 200

Item No.

049779

024024

Test load, max. (ram force, max.)

100

200

kN

Machine dimensions

overall height, approx.

1,635

1635

mm

table height

880

880

mm

height to tool head

1185

1185

mm

width

850

850

mm

depth

1200

1200

mm

Approx. weight

650

650

kg

Punching force, max.

275

275

kN

Clamping force, max.

275

275

kN

Specimen dimensions

blank diameter (punchable)

118

118

mm

blank diameter insertable, max.

150

150

mm

blank diameter insertable (with centering finger), max.

105

105

mm

sheet metal strip width, max.

128

128

mm

sheet thickness, max.

6.4

6.4

mm

Tool/fixture dimensions

drawing-die outside diameter, max.

155

155

mm

drawing punch diameter, max.

60

60

mm

drawing-die outside diameter, max.

drawing punch diameter, max.

Reading accuracy, ram stroke

0.01

0.01

mm

Reading accuracy, ram force

0.01

0.01

kN

Reading accuracy, clamping force

0.01

0.01

kN

Reading accuracy, deep drawing speed

0.01

0.01

mm/s

Ram stroke (travel of deep draw piston)

0 - 80.

0 - 80.

mm

Deep drawing speed, max.

1200

1200

mm/min

Coolant water

coolant water connection

G1/2"

G1/2"

Coolant water req. at 20°C water temperature

4

4

l/min

Electrical supply data

Electrical supply

3 x 400

3 x 400

V (3 Ph/PE)

Power consumption

10

10

kVA

Frequency

50

50

Hz

Back-up fuse

25

25

A

400 kN / 600 kN

Type

BUP 400

BUP 600

Item No.

037359

049042

Test load, max. (ram force, max.)

400

600

kN

Machine dimensions

overall height, approx.

1850

1850

mm

table height

955

955

mm

height to tool head

1185

1180

mm

width

1048

1048

mm

depth

1775

1775

mm

Approx. weight

1600

2100

kg

Punching force, max.

400

600

kN

Clamping force, max.

400

600

kN

Specimen dimensions

blank diameter (punchable)

250

250

mm

blank diameter insertable, max.

250

250

mm

blank diameter insertable (with centering finger), max.

220

220

mm

sheet metal strip width, max.

260

260

mm

sheet thickness, max.

10

10

mm

Tool/fixture dimensions

drawing-die outside diameter, max.

250

250

mm

drawing-punch diameter, max.

120

120

mm

drawing-die outside diameter, max.

Reading accuracy, ram stroke

0.01

0.01

mm

Reading accuracy, ram force

0.01

0.01

kN

Reading accuracy, clamping force

0.01

0.01

kN

Reading accuracy, deep drawing speed

0.01

0.01

mm/s

Ram stroke (travel of deep draw piston)

0 - 120.

0 - 120.

mm

Deep drawing speed, max.

1000

1000

mm/min

Coolant water

coolant water connection

G3/4"

G3/4"

Coolant water req. at 20 °C water temperature

10

7

l/min

Coolant water req. at 20 °C water temperature

Electrical supply data

Electrical supply

3 x 400

3 x 400

V (3 Ph/PE)

Power consumption

17.5

17.5

kVA

Frequency

50

50

Hz

Back-up fuse

32

32

A

1000 kN

Type

BUP 1000

Item No.

632802

Test load, max. (ram force, max.)

1000

kN

Machine dimensions

overall height, approx.

1960

mm

table height

1076

mm

height up to tool head (w/o protective screen), approx.

1353

mm

width

1200

mm

depth

1970

mm

Approx. weight

2100

kg

Punching force, max.

1000

kN

Clamping force, max.

1000

mm

Specimen dimensions

blank diameter (punchable)

250

mm

blank diameter insertable, max.

250

mm

blank diameter insertable (with centering finger), max.

270

mm

sheet metal strip width, max.

260

mm

sheet thickness, max.

10

mm

Tool/fixture dimensions

drawing-die outside diameter, max.

250

mm

drawing-punch diameter, max.

120

mm

Reading accuracy, ram stroke

0.01

mm

Reading accuracy, ram force

0.01

kN

Reading accuracy, clamping force

0.01

kN

Reading accuracy, deep drawing speed

0.01

mm/s

Ram stroke (travel of deep draw piston)

0 - 150.

mm

Deep drawing speed, max.

750

mm/min

Coolant water

coolant water connection

G3/4"

Coolant water req. at 20°C water temperature

10

l/min

Electrical supply data

Electrical supply

3 x 400

V (3 Ph/PE)

Power consumption

16

kVA

Frequency

50

Hz

Back-up fuse

32

A

Sheet metal testing for innovative materials

Sheet-metal forming is a basic metalworking and metal-processing technique and is among the oldest production technologies. Innovation is largely driven by transport technology, particularly the automotive industry. Increasing demands on sheet-metal materials under the general heading of lightweight construction have led to the development of high-tensile and ultra-high-tensile steel materials, although their reduced ductility and higher elastic recovery are setting new challenges for forming technology and process control.

Sheet metal testing machines assist in the process of development in characterizing new alloys and new metalworking technologies, as well as in eventual series production. Zwick sheet metal testing machines score with their flexibility, fast, easy fixture changes for different tests and individually controllable integrated functions such as holding down, punching, drawing and ejection.

Typical sheet-metal forming applications include the classical Erichsen cupping test (EN ISO 20482), the earing test (EN 1669) and hole-expansion tests, which are seeing increasing use with high-tensile steel materials.

Particular importance is attached to determination of the forming limit curve (FLC), which is used in a two-stage experiment to generate critical deformations in tests. These are then compared with existing deformations on actual components and evaluated. Once the FLC has been determined, it is used at the component design stage to help optimize forming, thereby speeding up the development process. In addition to a sheet metal testing machine, these tests (ISO 12004) require a suitable optical evaluation system.

Spring-back properties are generally determined on customer-specific specimens. Similarly, customized fixtures incorporated into the sheet metal testing machine allow tests to be performed quickly and easily.

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