Shearing is a cutting operation that removes a blank from a sheet. The edges are neither smooth nor perpendicular. Clearance between the punch and die is 2-10% of sheet thickness. Shearing includes punching, blanking, piercing, notching, trimming, and nibbling. Punching removes material that is discarded while blanking removes material that is the useful part. Die size equals blank size for blanking while punch size is smaller than blank size. Deep drawing occurs when cup height is over 0.5 times the diameter. Ironing reduces wall thickness uniformly through a clearance, lengthening the part and reducing thickness by 40-60%.
Shearing is a cutting operation that removes a blank from a sheet. The edges are neither smooth nor perpendicular. Clearance between the punch and die is 2-10% of sheet thickness. Shearing includes punching, blanking, piercing, notching, trimming, and nibbling. Punching removes material that is discarded while blanking removes material that is the useful part. Die size equals blank size for blanking while punch size is smaller than blank size. Deep drawing occurs when cup height is over 0.5 times the diameter. Ironing reduces wall thickness uniformly through a clearance, lengthening the part and reducing thickness by 40-60%.
Shearing is a cutting operation that removes a blank from a sheet. The edges are neither smooth nor perpendicular. Clearance between the punch and die is 2-10% of sheet thickness. Shearing includes punching, blanking, piercing, notching, trimming, and nibbling. Punching removes material that is discarded while blanking removes material that is the useful part. Die size equals blank size for blanking while punch size is smaller than blank size. Deep drawing occurs when cup height is over 0.5 times the diameter. Ironing reduces wall thickness uniformly through a clearance, lengthening the part and reducing thickness by 40-60%.
blank of required dimensions from a large sheet • cut edges are neither smooth nor perpendicular to the plane of the sheet • The clearance between the punch and the die - 2 to 10% of the sheet thickness Straight line shear
• Shearing may also be done between a punch and
die that include punching, blanking, piercing, notching, trimming, and nibbling. Punching • Punching - process in which the punch removes a portion of material from the larger piece or a strip of sheet metal. • The small removed piece is discarded Blanking • Blanking - process in which the punch removes a portion of material from the larger piece or a strip of sheet metal. • The small removed piece is the useful part and the rest is scrap Die size = Blank size, and the punch is made smaller, by considering the clearance 2 degree of angular clearance is sufficient. The height of cutting land of about 3 mm is generally sufficient. Stripper • Thick material,hole at centre, close punches – more Fstripper
Fstripper = 2.5% to 20% of Fpunch
• The maximum force, P required to be exerted by the punch to shear out a blank from the sheet can be estimated as P = t. L.τ where t is the sheet thickness, L is the total length sheared (such as the perimeter of hole), and τ is the shear strength of the sheet material Clearance c = At, where, A is clearance allowance t is sheet thickness. The clearance allowance A is taken to be 0.075 for most of the steels and 0.045 for aluminium alloys. Blanking Die size = blank size Punch size = blank size – 2 x clearance Clearance = k . t . t where t is the shear strength of material, t is the thickness of sheet metal stock, and k is a constant whose value may be taken as 0.003 Punching Punch size = blank size Die size = blank size + 2 x clearance Clearance = k . t . t A circular blank of 30 mm diameter is to be cut from 2 mm thick 0.1 C steel sheet. Determine the die and punch sizes. Also estimate the punch force required. Assume the following for the steel : Tensile strength: 410 MPa ; shear strength : 310 MPa For cutting a blank, die size = blank size \ Die size = 30mm Clearance = 0.003 x t x t = 0.003 x 2 x 310 = 1.86 mm Punch size = blank size – 2 clearance = 30 – (2 x 1.86) = 26.28 mm Punch force needed = L. t. t = p x 30 x 2 x 310 = 58.5 kN Piercing Piercing is process in which punch operation cuts a hole / material by tearing operation from a final piece of sheet metal. Notching, Trimming, Nibbling Problem 2: Determine the die and punch sizes for blanking a circular disc of 20 mm diameter from a C20 steel whose thickness is 1.5 mm. The Shear strength of C20 steel is 294 Mpa. Blanking operation: Die size = blank size Punch size = blank size – (2 x clearance)
Die size = blank size = 20 mm
Clearance = a.t = 0.075 x 20 = 1.5 mm
Punch size = 20 – (2x1.5) = 17 mm
What if piercing operation???? Piercing operation Punch size = blank size Die size = blank size + (2 x clearance)
Punch size = blank size = 20 mm
Die size = 20 + (2 x 1.5) = 23 mm What will be the Punching and stripper force??? Fpunching = P.t.Ʈ, = πd.t.Ʈ = π x 20 x 1.5 x 294 = 27.7 kN
Fstripper = 5% of Fpunch (assuming)
= 0.05 x 27.7 = 1.39 kN Punch radius (r) = 4 to 10 t Die radius (R) = 4 t normal = 6 to 8 t (when blank holder is used) = 0.8 (D-d) t Clearanace = 7 to 20% t Drawing force = πdtY[(D/d)-C] Y – Yield strength (Mpa) C – constant to cover friction and bending (0.6 to 0.7) Deep Drawing • When cup height > 0.5 diameter Ironing • Ironing of sheet metal is a manufacturing process that is mostly used to achieve a uniform wall thickness in deep drawings • A punch and die pushes the part through a clearance that will act to reduce the entire wall thickness to a certain value. • While reducing the entire wall thickness, ironing will cause the part to lengthen. • The percentage reduction in thickness for an ironing operation is usually 40% to 60%.