Metal Forming & Machining

(MF F313)
BITS Pilani K S SANGWAN
Pilani Campus
Outline

Deep Drawing
Bending
Punching and Blanking

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Press Working

Deep Drawing
Bending
Punching & Blanking (Shearing)

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 BITS Pilani
Pilani Campus

Deep Drawing Process

 Deep Drawing

Fig (a) Schematic illustration Fig (b) Process of deep drawing.

of the deep-drawing process
on a circular sheet-metal
blank.
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Deep Drawing

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Analysis of Deep Drawing
Process

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Important Variables in deep
drawing

Blank holding force

Clearance between punch and die
Punch and die corner radii
Ratio of blank dia to die dia
Friction and lubrication
Sheet metal properties

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Blank Holding Force

F|h    rj2 K, where is between0.02 and 0.08

Too less – wrinkling

Too high – increases punch force, tearing

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Clearance

7% - 14% greater than sheet thickness

Too small – piercing/shearing of blank
Too large – non uniform walls (thicker at rim and thinner at
base. Made uniform by Ironing process)

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Corner radii of the Punch &
Die
Too small – fracture at the corners
Too large – wrinkling

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 Redrawing

Why Redrawing?
[As the drawing ratio
increases, the stresses
developed also
increases. Hence there
is a limit on the
maximum drawing ratio
which can be achieved
in one draw]

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Lubrication

Lowers forces
Increases drawability
Reduces wears on the tooling
Reduces defects

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Job Stripping & Trimming

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 Deep
Too small blank
Drawing Defects
Too large blank
holding force holding force

anisotropy

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The metal-
forming
processes
involved in
manufacturing
a two-piece
aluminum
beverage can

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 BITS Pilani
Pilani Campus

Bending
Bending

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Minimum Bend Radius

As bend radius decreases, the tensile stress in the outer

fiber increases which leads to cracking of the sheet
It is a function of (c)
– Sheet thickness
– Ductility of sheet material
– Edge roughness
– Inclusions
– Anisotropy

(a) (b)

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 Springback increases
with the increase in
R/T ratio and yield
stress and decrease in
modulus of elasticity
The part tends to recover
elastically after bending,
and its bend radius
becomes larger.
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Methods of reducing or eliminating
springback in bending operations
•Overbending •Stretch Bending
•Bottoming/Spanking •Bending at high temperatures

Overbending Bottoming/Spanking

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Bending Operations

Common die-bending
operations, showing the
die-opening dimension,
W, used in calculating
bending forces.

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Bending Operations

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Bending in a Press Brake

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Bead Forming

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Flanging

(a) Flanges on a flat sheet. (b) Dimpling. (c) The piercing of sheet metal to
form a flange. (d) The flanging of a tube
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Tube Bending

Internal mandrels, or the filling of tubes with particulate materials such as sand, are often
necessary to prevent collapse of the tubes during bending. Solid rods and structural shapes can
also be bent by these techniques.
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Bulging

(a) The bulging of a tubular part with a flexible plug.

(b) Production of fittings for plumbing, by expanding tubular blanks
under internal pressure.
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Stretch Forming

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Conventional Spinning

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 Shear
Spinning

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Explosive Forming

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Magnetic-Pulse Forming
(a)

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 BITS Pilani
Pilani Campus

Punching and Blanking

Punching and Blanking

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Punching

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Mode of Metal Deformation &
Failure

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Effects of Punch/Die
Clearance

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Clearance (c)

c  0.0032 t τ (mm)
t  Sheet Thickness (mm)
τ  Material Shear Stress (MPa)

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Angular Clearance/Draft

The enlarged die opening

(after the final breaking, the
slug will spring back due to
release of elastic energy and
this will make blank to cling to
the die face unless the die
opening is enlarged)

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Stripper
Separate the punch from the stock (gripping
due to release of elastic energy)
Stripping Force (Ps )  kLt 
L  perimeter of cut
k  stripping constant (0.01 - 0.025)

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Punching Force

P  L t τ (for holes bigger tha n thickness)

dts
P (for holes smaller than thickness)
3 d
t
s  tensile strength of stock
d  diameter of punch

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Shear

To reduce maximum force or capacity of press

Distributes the cutting action over a period of time

No effect on total work done

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Punch travel and Blank
separation

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Shear Mechanism

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Types of shears

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Other Sheet Metal operations
Trimming: Cutting of Flash
Nibbling:Removal of metal in small increments when a specific
contour is to be cut on the sheet. Used when separate
punch is impractical & uneconomical
Notching: Cutting of small portion of sheet from edge
Lancing: making partway cuts without producing any scrap.
(Louver)
Slitting: lengthwise cuts to produce narrower strips

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Type of Dies

Simple Dies: Perform single operation for each stroke of the

press slide
Compound Dies: two or more operations (cutting) may be
performed at one station. Simple operations. Slow process.
Combination Dies: two or more operations (cutting + forming)
may be performed at one station
Progressive Dies: It has a series of stations. At each station, an
operation is performed on a workpiece during a stroke of the
press. Between strokes, the piece in the metal strip is
transferred to the next station. High production rate.
Transfer Dies: unlike progressive dies where the stock is fed
progressively from one station to another, in transfer dies the
already cut blanks are fed mechanically from station to station

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Compound Die

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Progressive Die

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Forming of the top piece of an aerosol
spray can in a progressive die

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Punching

Punch is size
Shear on punch
Punch size = Blank size
Die size = Blank (Punch) size + 2c

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Blanking

Die is size
Shear on Die
Die size = Blank size
Punch size = Blank (Die) size - 2c

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Thanks

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