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ManufacTechLecture 3
ManufacTechLecture 3
Lecture 3
EMU 1
SHEET METAL WORKING
1. Cutting Operations
2. Bending Operations
3. Drawing
4. Other Sheet Metal Forming Operations
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Sheet Metalworking Defined
Cutting and forming operations performed on relatively
thin sheets of metal
Thickness of sheet metal = 0.4 mm (1/64in) to 6mm
(1/4 in)
Thickness of plate stock > 6 mm
Operations usually performed as cold working
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Sheet and Plate Metal Products
Sheet and plate metal parts for consumer and
industrial products such as
Automobiles and trucks
Airplanes
Railway cars and locomotives
Farm and construction equipment
Small and large appliances
Office furniture
Computers and office equipment
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Advantages of Sheet Metal Parts
High strength
Good dimensional accuracy
Good surface finish
Relatively low cost
Economical mass production for large
quantities
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Sheet Metalworking Terminology
Punch-and-die - tooling to perform cutting,
bending, and drawing
Stamping press - machine tool that performs
most sheet metal operations
Stampings - sheet metal products made by
press machine
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Basic Types of Sheet Metal Processes
1. Cutting
Shearing to separate large sheets
Blanking to cut part perimeters out of
sheet metal
Punching/ Piercing to make holes in sheet
metal
2. Bending
Straining sheet around a straight axis
3. Drawing
Forming of sheet into convex or concave
shapes
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Shearing, Blanking, and Punching
Three principal operations in press working that
cut sheet metal:
Shearing
Blanking
Punching
Piercing
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Sheet Metal Cutting - Shearing
Shearing of sheet metal between two cutting edges: (1) just before
the punch contacts work;
(2) punch begins to push into work, causing plastic deformation;
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Sheet Metal Cutting - Shearing
….
…….. Piercing tool
Punching tool
Bur
Punching Piercing
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Punching: operation
1. Punch, made of hardened steel, is forced through a work-piece.
2. The punch cuts the metal and separates it in the form of scrap
3. The hole size depends on the punch size
Characteristics:
Ability to produce economical holes in both strip and sheet metal during
medium or high production processes.
The ability to produce holes of varying shapes - quickly
Punching is an
operation of cutting
holes into a sheet blank
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Other shearing processes
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Close tolerances and low v
Clearance
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Clearance in Sheet Metal Cutting
Definition: Distance between punch cutting edge and die
cutting edge
Blanking
Diameter of punch = Db - 2c
Punching
Diameter of die = Dh + 2c
Punch and Die Sizes
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Angular Clearance
Purpose: allows slug or blank to drop through die
Typical values: 0.25 to 1.5 on each side
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Cutting Forces
F=StL
where S = shear strength of the metal; t = stock
thickness,
L = length of cut edge (contact length)
For circular= 2*3.14* R
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Example Problem
C= At
Punch size =
die size - 2C
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Example
F=StL
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Sheet Metal Bending
Straining sheet metal to take a permanent bend
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Sheet Metal Bending
Metal below the neutral axis is
compressed, while metal above the
neutral axis is stretched
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Types of Sheet Metal Bending
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V-Bending
Performed on a brake press
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Edge Bending
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Springback
Increase in included angle of bent part relative to
included angle of forming tool after tool is
removed
As the material is bent, the inner region of the bend is compressed while
the outer region is stretched, so the molecular density is greater on the
inside of the bend than on the outer surface. This causes the material to try
to return to its flat position.
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Spring back (SB)
SB= (α’-α’b)/α’b
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Bending Force
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Die Opening Dimension
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Bend Angle
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Bend Allowance Ab
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Bend Allowance
Bend angle
Included angle
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Example 20.2
-
Example 20.2
- for v type die
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Drawing
Sheet metal forming to make cup-shaped,
box-shaped, or other complex-curved,
hollow-shaped parts
Sheet metal blank is positioned over die cavity
and then punch pushes metal into opening
Products: beverage cans, ammunition shells,
automobile body panels
Also known as deep drawing (to distinguish it
from wire and bar drawing)
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Drawing
(a) Drawing of
cup-shaped part: (1)
before punch
contacts work, (2)
near end of stroke;
(b) work-part: (1)
starting blank, (2)
drawn part.
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Clearance in Drawing
Sides of punch and die separated by a
clearance c given by:
c = 1.1 t
where t = stock thickness
In other words, clearance is about 10% greater
than stock thickness
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Mechanics of Drawing
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Defects in Sheet Drawing
,
Drawing Without Blank Holder & Ironing
Condition
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Measures of Drawing Severity
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Forces in Sheet Drawing
Drawing force required by punch:
Effect of :
Higher holding forces
Smaller holding forces EMU
Stretch Forming
Sheet metal is stretched and simultaneously
bent to achieve shape change
Stretch forming: (1) start of process; (2) form die is pressed into the
work with force Fdie, causing it to be stretched and bent over the
form. F = stretching force.
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Force Required in Stretch Forming
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Roll Bending
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Spinning
Metal forming process in which an axially symmetric
part is gradually shaped over a rotating mandrel using
a rounded tool or roller
Products: Automobile parts, Utensils, Aerospace parts
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Types of Spinning
Three types:
1. Conventional spinning
2. Shear spinning
3. Tube spinning
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Conventional Spinning
1. Process is completed in several passes
2. Thinning occurs but not to great extent
3. Thin blanks are used
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Tube Spinning
Tube spinning is used to produce tubes and cylinders
As the roller moves in axial direction, the thickness reduces and
the length increases.
The roller touches the parts of the tubular blank, the
deformation is local.
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