Sheet Metal Forming

Chapter 20
 SHEET METALWORKING
1. Cutting Operations
2. Bending Operations
3. Drawing
4. Other Sheet Metal Forming Operations
 Assignment No. 2
 With the help of neat sketches, describe in
detail the processes of Tube Forming and
Tube Bending

 Only hand-written assignments are admissible

 Last date of submission: _20th April, 2017___

 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
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
Advantages of Sheet Metal Parts
 High strength
 Good dimensional accuracy
 Good surface finish
 Relatively low cost
 Economical mass production for large
quantities
 Sheet Metalworking Terminology
 Punch‑and‑die - tooling to perform cutting,
bending, and drawing
 Stamping press - machine tool that performs
most sheet metal operations
 Stampings - Stamping (also known as
pressing) is the process of placing flat sheet
metal in either blank or coil form into a
stamping press where a tool and die surface
forms the metal into a net shape.sheet metal
products
Stamping
 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 is a manufacturing process that produces a V-shape,
U-shape, or channel shape around a straight axis in ductile
materials, most commonly sheet metal.
3. Drawing is a metalworking process which uses tensile forces
to stretch metal. As the metal is drawn (pulled), it stretches
thinner, into a desired shape and thickness. It is classified in
two types: sheet metal drawing and wire, bar, and tube
drawing.
 Forming of sheet into convex or concave shapes
Shearing, Blanking, and Punching
Three principal operations in pressworking that
cut sheet metal:
 Shearing
 Blanking
 Punching
 Piercing
 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;
 Sheet Metal Cutting - Shearing

Shearing of sheet metal between two cutting edges: (3) punch

compresses and penetrates into work causing a smooth cut surface;
(4) fracture is initiated at the opposing cutting edges which separates
the sheet.
 Shearing
Sheet metal cutting operation along a straight line
between two cutting edges
 Typically used to cut large sheets

Shearing operation: (a) side view of the shearing operation;

(b) front view of power shears equipped with inclined
upper cutting blade.
 Shearing
 Shearing is a process for cutting sheet metal to size out
of a larger stock such as roll stock.

 Shears are used as the preliminary step in preparing stock

for stamping processes, or smaller blanks for CNC
presses

 The shearing process produces a shear edge burr, which

can be minimized to less than 10% of the material
thickness. The burr is a function of clearance between the
punch and the die, and the sharpness of the punch and
the die.
 Blanking and Punching
Blanking - sheet metal cutting along a closed line in
a single step to separate piece (called a blank)
from surrounding stock
Punching - similar to blanking except cut piece is
scrap, called a slug

(a) Blanking and (b) punching.

 Punching and Piercing
 A slug (the material punched out) is produced in
punching operations but not in piercing work
 Piercing is “forming a hole in sheet metal with a
pointed punch with no metal fallout (slug).”
 In this case, a significant burr or deformed sharp edge
is created on the bottom side of the material being
pierced.
PUNCHES

PIERCE
 Punching
 Punching is a metal fabricating process that
removes a scrap slug from the metal workpiece
each time a punch enters the punching die. This
process leaves a hole in the metal workpiece
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
 The punching process forces a steel punch, made of
hardened steel, into and through a workpiece.
 The punch diameter determines the size of the hole
created in the workpiece
 Punching is often the cheapest method for creating
holes in sheet metal in medium to high production.
Punch Tools
 Piercing
 Piercing is the operation of cutting internal
features (holes or slots) in stock, without
forming slug scrap
 Clearance in Sheet Metal Cutting
Clearance ‘C’ is the distance between punch cutting edge and die cutting
edge
 Typical values in conventional press working range between 4% and
8% of sheet metal thickness ’t’
 If too small, fracture lines pass each other, causing double buffing and
larger force
 If too large, metal is pinched and bent between cutting edges and
excessive burr results
 Clearance in Sheet Metal Cutting
 Clearance ‘C’ in a shearing operation is the distance between Punch
and die Recommended clearance is calculated by:
c = A ct
where c = clearance; Ac = allowance; and t = stock thickness
 Allowance a is determined according to type of metal
• Low “Ac” for soft materials
 High “Ac” for hard materials
 Typical “Ac” values for metals range from 0.04 to 0.09
Example 20-1: Clearance
 Punch and Die Sizes
 For a round blank of diameter Db:
 Blanking die diameter = Db
 Blanking punch diameter = Db - 2c
where c = clearance
 For a round hole of diameter Dh:
 Hole punch diameter = Dh
 Hole’s Die diameter = Dh + 2c
where c = clearance
 Punch and Die Sizes

Die size determines blank

size Db;
Punch size determines
hole size Dh.;
c = clearance
 Angular Clearance
Purpose: allows slug or blank to drop through die
 Typical values: 0.25 to 1.5 on each side
 Cutting Forces
Important for determining press size (tonnage)
F=StL
where S = shear strength of the metal; t =
stock thickness, and L = length of cut edge
 Other Sheet Metal Cutting Operations
 Cutting Off:

 Parting:
 Slotting, Perforating and Notching:
Trimming, Shaving, and Fine Blanking
 Sheet Metal Bending
Straining sheetmetal around a straight axis to
take a permanent bend

Bending of sheet metal

 Sheet Metal Bending
Metal on inside of neutral plane is compressed,
while metal on outside of neutral plane is
stretched

•The material is stressed beyond the

yield strength but below the ultimate
tensile strength.
•The surface area of the material does
not change much.
•Bending usually refers to deformation
about one axis
 Types of Sheet Metal Bending
 V‑bending
-performed with a V‑shaped punch and die for low production volume.
-included angle ranging from acute to obtuse angle
-performed oftenly with brake press
-V-dies are simple and inexpensive
 Edge bending – involve cantilever loading of sheet metal. A
pressure pad is also used to apply a force Fh to hold the base of part
against die. It is performed with a wiping die and punch to bend
 -used for high production
 Engineering Analysis of Bending
 If bend radius is small relative to stock thickness,
metal tends to stretch during bending
 Important to estimate amount of stretching, so final
part length = specified dimension.
 Sheet metal with thickness t is bent thru an angle
called bend angle ‘α’
 This results into angle
 where

 The bend radius R is specified on inside of part

rather than on neutral axis
Engineering Analysis of Bending: Bend
Allowance Formula
The length of neutral axis before bending to account for
stretching, called bending allowance Ab, is calculated as

where Ab = bend allowance;  = bend angle; R= bend

radius; t = stock thickness; and Kba is factor to
estimate stretching
 If R < 1.7t, Kba = 0.33
 If R  1.7t, Kba = 0.50
Engineering Analysis of Bending: Springback
 Increase in included angle of bent part relative
to included angle of forming tool after tool is
removed
 Reason for springback:
 When bending pressure is removed, elastic
energy remains in bent part, causing it to
recover partially toward its original shape
 Engineering Analysis of Bending: Springback

 

Springback in bending is seen as a decrease in bend angle and an increase in bend

radius: (1) during bending, the work is forced to take radius Rb and included angle b'
of the bending tool, (2) after punch is removed, the work springs back to radius R
and angle ‘.
Engineering Analysis of Bending: Bending Force

Maximum bending force estimated as follows:

where F = bending force; TS = tensile

strength of sheet metal; w = part width in
direction of bend axis; and t = stock
thickness. For V- bending, Kbf = 1.33; for
edge bending, Kbf = 0.33; D is opening width
of a V-die or wiping die
 Die Opening Dimension

Die opening dimension D: (a) V‑die, (b) wiping die.

 Example 20-2: Sheet Bending

Solution
 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)
 Drawing

(a) Drawing of
cup‑shaped part: (1)
before punch
contacts work, (2)
near end of stroke;
(b) workpart: (1)
starting blank, (2)
drawn part.
 Clearance in Drawing
 Blank Dia, Db is drawn into a die by means of punch
of Dia, Dp.
 Punch and Die must have radii Rp, and Rd
respectively, otherwise hole punching would
start with zero radii
 Sides of punch and die are 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
Stages in Drawing
 Engineering Analysis

DR≤2.0
Second to characterize the drawing
is through reduction, r
r=0.5

Third way is t/Db ˃1%

 Example 20-3 : Drawing

So Drawing Operation is feasible

Example 20-4: Forces in Drawing Operation
 Sheet Metal Operations not performed on Presses
1. 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.
Force Required in Stretch Forming

where F = stretching force; L = length of sheet in

direction perpendicular to stretching; t =
instantaneous stock thickness; and Yf = flow
stress of work metal
 Die force Fdie can be determined by balancing
vertical force components
 Roll Bending
Large metal sheets and plates are formed into
curved sections using rolls
 Roll Forming

Roll forming involves feeding a lone strip or coil through

rotating rolls so that the shape of the rolls is imparted to
the strip while roll bending involves the forming of large
sheet and plate metal sections into curved forms..
 Spinning
Metal forming process in which an axially
symmetric part is gradually shaped over a
rotating mandrel using a rounded tool or roller
 Three types:
1. Conventional spinning
2. Shear spinning
3. Tube spinning
 Conventional Spinning

Conventional spinning: (1) setup at start of process; (2) during

spinning; and (3) completion of process.
 Shear Spinning
 A sheet-metal-forming process which forms parts with
rotational symmetry over a mandrel with the use of a
roller in which deformation is carried out with a roller in
such a manner that the diameter of the original blank
does not change but the thickness of the part decreases
by an amount dependent on the mandrel angle.
 Tube Spinning
 Tube spinning is recognized as an effective
process for producing large thin-wall cylindrical
workpieces
 In tube spinning, where the tubular blank rotates
with the mandrel whilst the roller undergoes axial
feeding movement, the thickness reduces and
the length increases.
 The roller touches the parts of the tubular blank,
and the plastic area is only in the region of the
part around the contact zone, so that the
deformation is restrained strongly by the
surrounding metal.
Tube Spinning
 Problem 20-9

 A bending operation is to be performed on 5 mm thick cold rolled steel.

Determine the blank size required
From drawing, α’ = 40°, R = 8.5 mm
α = 180 - α’ = 120°.
Ab = 2π(α /360)(R + Kbat)
R/t = 9.5/4.75 =2.0
R/t = (8.5)/5 = 1.7; therefore, Kba = 0.5
Ab = 2π(140/360)(8.5 + 0.5 x 5) = 26.88 mm
Dimensions of starting blank: w = 35 mm, L = 58 + 26.88 + 46.5 = 131.4
mm
 Problem 20-11
 An L-shaped part is to be bent in a V-bending operation on a
press brake from a flat blank 4.0” X 1.5” that is 5/32 inch
thick. The bend of 90° is to be made in the middle of the 4”
length. (a) Determine the dimensions of the two equal sides
that will result after the bend, if the bend radius = 3/16 inch.
For convenience, these sides should be measured to the
beginning of the bend radius. (b) Also, determine the length
of the part's neutral axis after the bend.
(a) R/t = (3/16)/(5/32) = 1.2. Therefore, Kba = 0.33
BA = 2π(90/360)(0.1875 + 0.33 x 0.15625) = 0.3756 in.
Dimensions (lengths) of each end= (½)(4.0 - 0.3756) = 1.8122
in.
(b) Since the metal stretches during bending, its length
will be greater after the bend than before.
Its length before bending = 4.000 in. The stretched length
of the bend along the neutral axis will be:
R/t = [(3/16) + t/2] /(5/32) = 1.7. Therefore, Kba = 0.5
BA = 2π(90/360)(0.1875 + 0.5 x 0.15625) = 0.4173 in.
Therefore, the length of the neutral axis of the part will be
2(1.8122) + 0.4173 = 4.0417 in.
 Problem 20-25: Other operations
 A drawing operation is performed on 3.0 mm stock. The
part is a cylindrical cup with height = 50mm and inside
diameter = 70 mm. Assume the corner radius on the punch
= zero. Find the required starting blank size D. Use surface
area computation, assuming thickness t remains constant.
Cup area = wall area + base area = πDph + πDp2/4 = π(70)
(50) + 0.25π(70)2 = 14,846 mm2.
Blank area = πD2/4 = 0.7855D2
Setting blank area = cup area: 0.7855D2 = 14,846
D2 = 14,846/0.7855 = 18,900
D = 137.48 mm.
Problem 20-30:Other operations
A 20 inch long sheet metal workpiece is stretched
in a stretch forming operation to the dimensions
shown in Figure (a). The thickness of the
beginning stock t = 0.125 inch and the width = 10
inches. The metal has a flow curve defined by K =
70,000 lb/in2 and n = 0.25. (a) Find the stretching
force F required near the beginning of the
operation when yielding first occurs. Determine:
(b) true strain experienced by the metal, (c)
stretching force F, and (d) die force Fdie at the very
end when the part is formed as indicated in Figure
(b)
 a) Use ε = 0.002 as start of yielding.
F = LtYf
Yf = 70,000(0.002)0.25 = 14,803 psi
F = (10)(0.125)(14,803) = 17,764 lbs.
(b) After stretching, the length of the piece is increased from 20.0 in. to 2(10 2
+ 52)0.5 = 22.361 in.
ε = ln(22.361/20) = ln 1.118 = 0.1116
(c) At the final length of 22.361 in., the thickness of the sheet metal has been
reduced to maintain constant volume, assuming width L = 10 in. remains the
same during stretching.
tf = 0.125(20/22.361) = 0.1073 in.
Yf = 70,000(0.1116)0.25 = 40,459 psi
F = 10(0.1073)(40,459) = 43,413 lbs.
(d) Fdie = 2F sin A
A = tan-1(5/10) = 26.57°
Fdie = 2(43,413) sin 26.57 = 38,836 lbs
 Problem 20-3: Cutting
A compound die will be used to blank and punch a large
washer out of aluminum alloy sheet stock 3.2 mm thick. The
outside diameter of the washer = 65 mm and the inside
diameter = 30 mm. Determine: (a) the punch and die sizes for
the blanking operation, and (b) the punch and die sizes
for the punching operation. Use a = 0.045.
c = 0.045(3.2) = 0.144 mm
(a) Blanking die diameter = Db = 65 mm
Blanking punch diameter = Db - 2c = 65 - 2(0.144) = 64.71 mm
(b) Punching punch diameter = Dh = 30 mm
Punching die diameter = Dh + 2c = 30 + 2(0.144) = 30.29 mm