ch20 - SHEET METALWORKING - Note
ch20 - SHEET METALWORKING - Note
2016
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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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• High strength
• Good dimensional accuracy
• Good surface finish
• Relatively low cost
• For large quantities, economical mass production
operations are available
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1. “Punch-and-die”
Tooling to perform cutting, bending, and drawing
2. “Stamping press”
Machine tool that performs most sheet metal
operations
3. “Stampings”
Sheet metal products
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Cutting
Shearing between two
sharp cutting edges
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Shearing
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Allowance a for
Three Sheet Metal Groups
Metal group a
1100S and 5052S aluminum alloys, all 0.045
tempers
2024ST and 6061ST aluminum alloys; brass, 0.060
soft cold rolled steel, soft stainless steel
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Figure 20.6 - Die size determines blank size Db; punch size
determines hole size Dh.; c = clearance
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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 metal; t = stock thickness,
and L = length of cut edge
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Bending
Straining sheetmetal around a straight axis to take a
permanent bend
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Figure 20.11 - (b) both compression and tensile elongation of the metal occur
in bending
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V-Bending
• For low production
• Performed on a press brake
• V-dies are simple and inexpensive
Figure 20.12 -
(a) V-bending
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Edge Bending
• For high production
• Pressure pad required
• Dies are more complicated and costly
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A
BA 2 (R K ba t )
360
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Springback in Bending
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Bending Force
K bf TSwt 2
F
D
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Figure 20.14 - Die opening dimension D: (a) V-die, (b) wiping die
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Drawing
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Figure 20.19 -
(a) Drawing of a
cup-shaped part:
(1) start of operation
before punch
contacts work
(2) near end of
stroke
(b) Corresponding
workpart:
(1) starting blank
(2) drawn part
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Clearance in Drawing
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Drawing Ratio DR
Db
DR
Dp
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Reduction r
Db Dp
r
Db
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Thickness-to-Diameter Ratio
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Ironing
• Makes wall thickness of cylindrical cup more uniform
• Examples: beverage cans and artillery shells
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Embossing
• Used to create indentations in sheet, such as raised
(or indented) lettering or strengthening ribs
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Guerin Process
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Figure 20.31 -
(a) Progressive
die;
(b) associated
strip
development
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Figure 20.34 -
Press brake with
bed width of
9.15 m (30 ft)
and capacity of
11,200 kN
(1250 tons);
two workers
are positioning
plate stock for
bending
(photo courtesy of
Niagara
Machine & Tool
Works)
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Figure 20.37 -
Straight-sided frame press
(photo courtesy Greenerd
Press & Machine
Company, Inc.)
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Stretch Forming
Sheet metal is stretched and simultaneously bent to
achieve shape change
Figure 20.39 - 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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F LtYf
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Roll Bending
Large metal sheets and plates are formed into curved
sections using rolls
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Roll Forming
Continuous bending process in which opposing rolls
produce long sections of formed shapes from coil or
strip stock
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Spinning
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Explosive Forming
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Electromagnetic Forming
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