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Lecture 12: Cutting (Shearing) and Bending: Processing of Metallic Materials

This document provides an overview of sheet metal cutting and bending processes. It discusses punching, blanking, bending terminology, bending forces, clearance requirements, and springback. The key topics covered are punching and blanking operations for cutting sheet metal, the importance of proper clearance between the punch and die, how bend allowance is calculated, and common bending techniques like V-bending and edge bending. Homework assignments involving problems and review questions on these sheet metal forming topics are also listed.

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104 views

Lecture 12: Cutting (Shearing) and Bending: Processing of Metallic Materials

This document provides an overview of sheet metal cutting and bending processes. It discusses punching, blanking, bending terminology, bending forces, clearance requirements, and springback. The key topics covered are punching and blanking operations for cutting sheet metal, the importance of proper clearance between the punch and die, how bend allowance is calculated, and common bending techniques like V-bending and edge bending. Homework assignments involving problems and review questions on these sheet metal forming topics are also listed.

Uploaded by

mukesh3021
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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MSE 440/540: Processing of Metallic Materials

Instructors: Yuntian Zhu


Office: 308 RBII Ph: 513-0559 [email protected]

Lecture 12: Cutting (Shearing) and Bending

Department of Materials Science and Engineering

NC State University

Sheet Metalworking Terminology


Punchanddie - tooling to perform cutting, bending,
and drawing

Stamping press - machine tool that performs most


sheet metal operations

Stampings - sheet metal products

(1) Just before punch; (2) punch pushes into work, causing plastic deformation; (3) punch penetrates into work; and (4) fracture is initiated
NC State University

Shearing, Blanking, and Punching


Three principal operations in pressworking that cut sheet metal:
Shearing (cutting) Blanking Punching

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Blanking and Punching


Blanking (a) - sheet metal cutting to separate piece (called a blank) from surrounding stock Punching (b) - similar to blanking except cut piece is scrap, called a slug

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Clearance in Sheet Metal Cutting


Distance between punch cutting edge and die cutting edge 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

C = clearance

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Clearance in Sheet Metal Cutting


Recommended clearance is calculated by: c = at where c = clearance; a = allowance; and t = stock thickness Allowance a is determined according to type of metal

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Sheet Metal Groups Allowances


Metal group 1100S and 5052S aluminum alloys, all tempers 2024ST and 6061ST aluminum alloys; brass, soft cold rolled steel, soft stainless steel Cold rolled steel, half hard; stainless steel, half hard and full hard a 0.045 0.060

0.075

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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
Important for determining press size (tonnage) F=StL where S = shear strength of metal; t = stock thickness, and L = length of cut edge

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Sheet Metal Bending


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

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Bend Allowance Formula


If bend radius is small relative to stock thickness, neutral axis becomes longer Problem: to determine the length of neutral axis of the part before bending

Ab = 2 ( R + K bat ) 360
where Ab = bend allowance; = bend angle; R= bend radius; t = stock thickness; and Kba is factor to estimate stretching If R < 2t, Kba = 0.33 If R 2t, Kba = 0.50

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V-Bending
(1) Before bending (2) After bending Application notes:
Low production Performed on a press brake V-dies are simple and inexpensive

http://www.youtube.com/watch?v=qTUMbVNf1Xc
NC State University

Edge Bending
(1) Before bending (2) After bending Application notes:
High production Pressure pad required Dies are more complicated and costly
http://www.youtube.com/watch?v=W6usvOZ9yIw

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Springback
When bending pressure is removed, elastic energy remains in bent part, causing it to recover partially toward its original shape

! !! " !b SB = ! !b

Need overbending to correct


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Bending Force
Maximum bending force estimated as follows:

K bf TSwt F= D

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
NC State University

Roll Bending
Large metal sheets and plates are formed into curved sections using rolls

http://www.youtube.com/watch?v=J09E_luT1pM
NC State University

HW assignment
Reading assignment: Chapters 15,16 Review Questions: 14.3, 14.6, 14.7, 14.8, Problems: 14.1, 14.2, 14.3, 14.8, 14.10,

Department of Materials Science and Engineering

17

NC State University

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