Manufacturing Processes (ME F219)

Prof Amrita Priyadarshini

Associate Professor
Department of Mechanical Engineering
 BITS Pilani
Hyderabad Campus

Metal Forming Processes

2
 Types
Surface area to volume ratio small
Entire volume is deformed

Surface area to volume ratio high

Thickness variation not desired

BITS Pilani, Hyderabad Campus

Determination of Drawing Force and Power
Assuming a cylindrical workpiece

Considering the radial equilibrium

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Axial stress σx as a function of r:
𝝁
𝝋 =𝟏+
𝒕𝒂𝒏 𝜶

Α value is always less than 90°, φ is

always positive and greater than 1

Maximum allowable reduction:

Power Required for Drawing

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BITS Pilani, Hyderabad Campus
BITS Pilani, Hyderabad Campus
SHEET METALWORKING
Cutting Operations
Bending Operations
Drawing
Other Sheet Metal Forming Operations
Dies and Presses for Sheet Metal Processes
Sheet Metal Operations Not Performed on Presses
Bending of Tube Stock

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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 (1/64 in) to 6 mm (1/4 in)
• Thickness of plate stock > 6 mm
• Operations usually performed as cold-working
• 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
For large quantities, economical mass production operations are available

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Three Major Categories of Sheet Metal Processes

1. Cutting
– Shearing to separate large sheets; or cut part perimeters or make holes in sheets

2. Bending
– Straining sheet around a straight axis

3. Drawing
– Forming of sheet into convex or concave shapes

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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
(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

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Shearing, Blanking, and Punching
Three principal operations in press working that cut sheet metal:
• Shearing: Sheet metal cutting operation along a straight line between two cutting
edges. Typically used to cut large sheets into smaller sections for subsequent
operations
• Blanking: sheet metal cutting to separate piece from surrounding stock
• Cut piece is the desired part, called a blank
• Punching - sheet metal cutting similar to blanking except cut piece is scrap,
called a slug
• Remaining stock is the desired part

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Blanking and Punching

(a) Blanking (b) Punching

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Clearance in Sheet Metal Cutting
Distance between the punch and die
Typical values range between 4% and 8% of stock thickness
– If too small, fracture lines pass each other, causing double burnishing and larger force
– If too large, metal is pinched between cutting edges and excessive burr results

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Punch and Die Sizes for Punching
Blanking:
For a round blank of diameter Db:
Blanking punch diameter = Db ‑ 2c
Blanking die diameter = Db
where c = clearance

Punching:
For a round hole of diameter Dh:
Hole punch diameter = Dh
Hole die diameter = Dh + 2c
where c = clearance

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 Blanking/Punching analysis
• The problem is 2D
• The thickness of the sheet is t, and clearance is c
• With the optimum clearance, the fracture line
should meet the die corner

Optimum clearance and penetration depth:

is the fracture strain of the workpiece

P is the penetration depth
Co is the optimum clearance

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Maximum punching force:
Fmax= σf Co L
σf = Fracture stress for the given wor kpiece
D = Punch Diameter
L = Length of cut = πD

Work required for punching operation:

W = Fmax p
Average force for a width of cut b:
Fmax= σf Co b (Shearing)
Maximum force occurs when the punch travels upto the penetration depth p
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Bending
• Straining sheet metal around a straight axis to take a permanent bend
• Metal on inside of neutral plane is compressed, while metal on outside of
neutral plane is stretched

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 Details in bending

Objectives:
• Determination of bending load and amount of
elastic recovery
• Estimation of elastic spring back, given the
final shape required, by suitable amount of
over bending
• Determination of the stock size for a given
bending operation

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The neutral axis is normally positioned
at the geometric centroid for a regular
or homogeneous (symmetric,
isotropic, and not curved) beam.

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Bending Analysis

Maximum true strain that occurs in the outer fibre of the bend:

εmax

If the strain crosses the maximum strain, fracture occurs.

εmax = εfracture (can be used to find the radius of the punch)

Rp: nose radius of the punch

t: thickness of the sheet being bent

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 Determination of the work load
• In the actual deformation, the strain in the inner fibres is elastic where as it is plastic towards the outer fibres
• Due to shift of neutral axis, like in curved beams, the yield strength on the tension and compression sides will
not be same
• Therefore, and are taken on the tension and the compression sides respectively
• When strain hardening rate is n, then

=+ nεmax

The equivalent bending moment and tensile force on cross section per unit width of job is given by:
The maximum work load per unit width is given by:

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Springback in 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

Springback in bending shows itself as a decrease in bend angle and

an increase in bend radius:
(1) during bending, the work is forced to take the radius Rb and
included angle Ab' of the bending tool (punch in V‑bending),
(2) after punch is removed, the work springs back to radius R and
angle A'

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Estimation of spring back

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BITS Pilani, Hyderabad Campus