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ch20 - SHEET METALWORKING - Note

The document discusses sheet metalworking processes including cutting, bending, and drawing operations. It describes shearing, blanking, and punching operations and provides examples of punch and die sizes and configurations for sheet metal cutting.

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yusuf yerli
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0% found this document useful (0 votes)
31 views35 pages

ch20 - SHEET METALWORKING - Note

The document discusses sheet metalworking processes including cutting, bending, and drawing operations. It describes shearing, blanking, and punching operations and provides examples of punch and die sizes and configurations for sheet metal cutting.

Uploaded by

yusuf yerli
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 35

24.3.

2016

YPALACI

GIM2042 Manufacturing Processes, Gr. 2, T.301

Lecturer; Assoc. Prof.Dr.Yüksel PALACI


Office ; T403
E-mail ; [email protected]

• Book; John Wiley & Sons, Inc. M. P. Groover,


“Fundamentals of Modern Manufacturing”
• Chapters:1,10,11,16,18-22,24,30-34
• http://www.bologna.yildiz.edu.tr/index.php?r=course/v
iew&id=1171&aid=35

Dept. of Naval Architecture and Marine Engineering

YPALACI

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

Dept. of Naval Architecture and Marine Engineering

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YPALACI

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

Dept. of Naval Architecture and Marine Engineering

YPALACI

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

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YPALACI

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

“” Dept. of Naval Architecture and Marine Engineering

YPALACI

Sheet Metalworking Terminology

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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YPALACI

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

“” Dept. of Naval Architecture and Marine Engineering

YPALACI

Cutting
Shearing between two
sharp cutting edges

Figure 20.1 - Shearing of


sheet metal between two
cutting edges:
(1) just before the punch
contacts work

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YPALACI

Figure 20.1 - Shearing of sheet


metal between two cutting
edges:
(2) punch begins to push into
work, causing plastic
deformation

Dept. of Naval Architecture and Marine Engineering

YPALACI

Figure 20.1 - Shearing of


sheet metal between two
cutting edges:
(3) punch compresses and
penetrates into work
causing a smooth cut
surface

Dept. of Naval Architecture and Marine Engineering

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YPALACI

Figure 20.1 - Shearing of sheet


metal between two cutting
edges:
(4) fracture is initiated at the
opposing cutting edges which
separates the sheet

Dept. of Naval Architecture and Marine Engineering

YPALACI

Shearing, Blanking, and Punching

Three principal operations in pressworking that cut


sheet metal:
• Shearing
• Blanking
• Punching

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YPALACI

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

Dept. of Naval Architecture and Marine Engineering

YPALACI

Figure 20.3 - Shearing operation:


(a) side view of the shearing operation
(b) front view of power shears equipped with inclined upper cutting blade
Symbol v indicates motion

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YPALACI

Blanking and Punching

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

Dept. of Naval Architecture and Marine Engineering

YPALACI

Figure 20.4 - (a) Blanking and (b) punching

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YPALACI

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

Dept. of Naval Architecture and Marine Engineering

YPALACI

Clearance in Sheet Metal Cutting

• Recommended clearance can be 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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YPALACI

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

Cold rolled steel, half hard; stainless steel, half 0.075


hard and full hard

Dept. of Naval Architecture and Marine Engineering

YPALACI

Punch and Die Sizes for


Blanking and Punching
For a round blank of diameter Db:
Blanking punch diameter = Db - 2c
Blanking die diameter = Db
where c = clearance
For a round hole of diameter Dh:
Hole punch diameter = Dh
Hole die diameter = Dh + 2c
where c = clearance

Dept. of Naval Architecture and Marine Engineering

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Figure 20.6 - Die size determines blank size Db; punch size
determines hole size Dh.; c = clearance

Dept. of Naval Architecture and Marine Engineering

YPALACI

Angular Clearance
Purpose: allows slug or blank to drop through die
• Typical values: 0.25 to 1.5 on each side

Figure 20.7 - Angular


clearance

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YPALACI

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

Dept. of Naval Architecture and Marine Engineering

YPALACI

Bending
Straining sheetmetal around a straight axis to take a
permanent bend

Figure 20.11 - (a) Bending of sheet metal

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YPALACI

Metal on inside of neutral plane is compressed, while


metal on outside of neutral plane is stretched

Figure 20.11 - (b) both compression and tensile elongation of the metal occur
in bending

Dept. of Naval Architecture and Marine Engineering

YPALACI

Types of Sheetmetal Bending

• V-bending - performed with a V-shaped die


• Edge bending - performed with a wiping die

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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

Dept. of Naval Architecture and Marine Engineering

YPALACI

Edge Bending
• For high production
• Pressure pad required
• Dies are more complicated and costly

Figure 20.12 - (b) edge bending

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Stretching during Bending

• If bend radius is small relative to stock thickness,


metal tends to stretch during bending
• Important to estimate amount of stretching, so that
final part length = specified dimension
• Problem: to determine the length of neutral axis of
the part before bending

Dept. of Naval Architecture and Marine Engineering

YPALACI

Bend Allowance Formula

A
BA  2 (R  K ba t )
360

where BA = bend allowance; A = 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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YPALACI

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

Dept. of Naval Architecture and Marine Engineering

YPALACI

Figure 20.13 - 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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YPALACI

Bending Force

Maximum bending force estimated as follows:

K bf TSwt 2
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

Dept. of Naval Architecture and Marine Engineering

YPALACI

Figure 20.14 - Die opening dimension D: (a) V-die, (b) wiping die

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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

Dept. of Naval Architecture and Marine Engineering

YPALACI

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

Dept. of Naval Architecture and Marine Engineering

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YPALACI

Clearance in Drawing

• Sides of punch and die separated by a clearance c


given by:
c = 1.1 t
where t = stock thickness
• In other words, clearance = about 10% greater than
stock thickness

Dept. of Naval Architecture and Marine Engineering

YPALACI

Drawing Ratio DR

Most easily defined for cylindrical shape:

Db
DR 
Dp

where Db = blank diameter; and Dp = punch diameter


• Indicates severity of a given drawing operation
 Upper limit = 2.0

Dept. of Naval Architecture and Marine Engineering

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YPALACI

Reduction r

• Again, defined for cylindrical shape:

Db  Dp
r
Db

• Value of r should be less than 0.50

Dept. of Naval Architecture and Marine Engineering

YPALACI

Thickness-to-Diameter Ratio

Thickness of starting blank divided by blank diameter


Thickness-to-diameter ratio = t/Db
• Desirable for t/Db ratio to be greater than 1%
• As t/Db decreases, tendency for wrinkling increases

Dept. of Naval Architecture and Marine Engineering

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YPALACI

Blank Size Determination

• For final dimensions of drawn shape to be correct,


starting blank diameter Db must be right
• Solve for Db by setting starting sheet metal blank
volume = final product volume
• To facilitate calculation, assume negligible thinning of
part wall

Dept. of Naval Architecture and Marine Engineering

YPALACI

Shapes other than Cylindrical Cups

• Square or rectangular boxes (as in sinks),


• Stepped cups,
• Cones,
• Cups with spherical rather than flat bases,
• Irregular curved forms (as in automobile body panels)

• Each of these shapes presents its own unique


technical problems in drawing

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Other Sheet Metal Forming on Presses

Other sheet metal forming operations performed on


conventional presses
• Operations performed with metal tooling
• Operations performed with flexible rubber tooling

Dept. of Naval Architecture and Marine Engineering

YPALACI

Ironing
• Makes wall thickness of cylindrical cup more uniform
• Examples: beverage cans and artillery shells

Figure 20.25 - Ironing to achieve a more uniform wall thickness in a


drawn cup: (1) start of process; (2) during process
Note thinning and elongation of walls

Dept. of Naval Architecture and Marine Engineering

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Embossing
• Used to create indentations in sheet, such as raised
(or indented) lettering or strengthening ribs

Figure 20.26 - Embossing: (a) cross-section of punch and die


configuration during pressing; (b) finished part with embossed ribs

Dept. of Naval Architecture and Marine Engineering

YPALACI

Guerin Process

Figure 20.28 - Guerin process: (1) before and (2) after


Symbols v and F indicate motion and applied force respectively

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Advantages of Guerin Process

• Low tooling cost


• Form block can be made of wood, plastic, or other
materials that are easy to shape
• Rubber pad can be used with different form blocks
• Process attractive in small quantity production

Dept. of Naval Architecture and Marine Engineering

YPALACI

Dies for Sheet Metal Processes

Most pressworking operations performed with


conventional punch-and-die tooling
• Custom-designed for particular part
• The term stamping die sometimes used for high
production dies

Dept. of Naval Architecture and Marine Engineering

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YPALACI

Figure 20.30 - Components of a punch and die for a blanking operation

Dept. of Naval Architecture and Marine Engineering

YPALACI

Figure 20.31 -
(a) Progressive
die;
(b) associated
strip
development

“” Dept. of Naval Architecture and Marine Engineering

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YPALACI

Figure 20.32 - Components of a typical mechanical


drive stamping press

Dept. of Naval Architecture and Marine Engineering

YPALACI

Types of Stamping Press Frame

• Gap frame – configuration of the letter C and often


referred to as a C-frame
• Straight-sided frame – box-like construction for higher
tonnage

Dept. of Naval Architecture and Marine Engineering

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YPALACI

Figure 20.33 - Gap frame


press for sheet
metalworking
(photo courtesy of E. W.
Bliss Company)
Capacity = 1350 kN (150
tons)

Dept. of Naval Architecture and Marine Engineering

YPALACI

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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YPALACI

Figure 20.35 - Several sheet metal parts produced on a turret


press, showing variety of hole shapes possible
(photo courtesy of Strippet, Inc.)

Dept. of Naval Architecture and Marine Engineering

YPALACI

Figure 20.36 - Computer numerical control turret press


(photo courtesy of Strippet, Inc.)

Dept. of Naval Architecture and Marine Engineering

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YPALACI

Figure 20.37 -
Straight-sided frame press
(photo courtesy Greenerd
Press & Machine
Company, Inc.)

Dept. of Naval Architecture and Marine Engineering

YPALACI

Power and Drive Systems

• Hydraulic presses - use a large piston and cylinder to


drive the ram
 Longer ram stroke than mechanical types
 Suited to deep drawing
 Slower than mechanical drives
• Mechanical presses – convert rotation of motor to
linear motion of ram
 High forces at bottom of stroke
 Suited to blanking and punching

Dept. of Naval Architecture and Marine Engineering

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YPALACI

Sheet Metal Operations


Not Performed on Presses
• Stretch forming
• Roll bending and forming
• Spinning
• High-energy-rate forming processes.

Dept. of Naval Architecture and Marine Engineering

YPALACI

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

Dept. of Naval Architecture and Marine Engineering

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YPALACI

Force Required in Stretch Forming

F  LtYf

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

Dept. of Naval Architecture and Marine Engineering

YPALACI

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

Figure 20.40 - Roll bending

Dept. of Naval Architecture and Marine Engineering

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YPALACI

Roll Forming
Continuous bending process in which opposing rolls
produce long sections of formed shapes from coil or
strip stock

Figure 20.41 - Roll


forming of a
continuous
channel
section:
(1) straight rolls
(2) partial form
(3) final form

Dept. of Naval Architecture and Marine Engineering

YPALACI

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

Dept. of Naval Architecture and Marine Engineering

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YPALACI

Figure 20.42 - Conventional spinning: (1) setup at start of process;


(2) during spinning; and (3) completion of process

Dept. of Naval Architecture and Marine Engineering

YPALACI

High-Energy-Rate Forming (HERF)

Processes to form metals using large amounts of


energy over a very short time
• HERF processes include:
 Explosive forming
 Electrohydraulic forming
 Electromagnetic forming

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YPALACI

Explosive Forming

Use of explosive charge to form sheet (or plate) metal


into a die cavity
• Explosive charge causes a shock wave whose
energy is transmitted to force part into cavity
• Applications: large parts, typical of aerospace
industry

Dept. of Naval Architecture and Marine Engineering

YPALACI

Figure 20.45 - Explosive forming:


(1) setup, (2) explosive is detonated, and
(3) shock wave forms part and plume escapes water surface

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YPALACI

Electromagnetic Forming

Sheet metal is deformed by mechanical force of an


electromagnetic field induced in workpart by an
energized coil
• Presently the most widely used HERF process
• Applications: tubular parts

Dept. of Naval Architecture and Marine Engineering

YPALACI

Figure 20.47 - Electromagnetic forming: (1) setup in which coil is


inserted into tubular workpart surrounded by die; (2) formed part

Dept. of Naval Architecture and Marine Engineering

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