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Bead Forming
FIGURE 7.25 (a) Bead forming with a single die. (b) Bead forming with two dies in a press
brake.
Flanging Operations
FIGURE 7.26 Various
flanging operations. (a)
Flanges on flat sheet. (b)
Dimpling. (c) Piercing sheet
metal to form a flange. in this
operation, a hole does not have
to be prepunched before the
punch descends. Note,
however, the rough edges
along the circumference of the
flange. (d) Flanging of a tube.
Note the thinning of the edges
of the flange.
Roll-Forming Process
Bending of Tubes
FIGURE 7.29 Methods of bending tubes. Using internal mandrels, or filling tubes with particulate
materials such as sand, is often necessary to prevent collapsing of the tubes during bending. Solid
rods and structural shapes are also bent by these techniques.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Bending
FIGURE 7.15 (a) Bending terminology. The bend radius is measured to the inner surface of
the bend. Note that the length of the bend is the width of the sheet. Also note that the bend
angle and the bend radius (sharpness of the bend) are two different variables. (b)
Relationship between the ratio of bend radius to sheet thickness and tensile reduction of area
for various materials. Note that sheet metal with a reduction of area of about 50% can be
bent and flattened over itself without crackling. Source: After J. Datsko and C. T. Yang.
MATERIAL CONDITION
SOFT
HARD
0
6T
0
4T
0
2T
5T
13T
0.5T
0.5T
0.7T
2.6T
TABLE 7.2 Minimum bend radii for various materials at room temperature.
6T
4T
3T
4T
Springback in Bending
FIGURE 7.18 Terminology for springback
in bending. Springback is caused by the
elastic recovery of the material upon
unloading. In this example, the material
tends to recover toward its originally flat
shape. However, there are situations where
the material bends farther upon unloading
(negative springback), as shown in Fig.
7.20.
Stretch-Forming Process