Lecture 6

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Lecture 6

BENDING

SHEET METAL PROCESSES

Bendingisoneverycommonsheetmetalformingoperationusednotonlytoformshapeslikeseams,corrugations,
andflangesbutalsotoprovidestiffnesstothepart(byincreasingitsmomentofinertia).

As a sheet metal is bent (Fig 6.1), its fibres experience a distortion such that those nearer its outside, convex
surfaceareforcedtostretchandcomeintension,whiletheinnerfibrescomeincompression.Somewhere,inthecross
section,thereisaplanewhichseparatesthetensionandcompressionzones.Thisplaneisparalleltothesurfacearound
which the sheet is bending, and is called neutral axis. The position of neutral axis depends on the radius and angle of
bend.Further,becauseofthePoisson'sratio,thewidthofthepartLintheouterregionissmaller,andintheinnerregionit
islarger,thantheinitialoriginalwidth.

Fig 6.1 Sheetmetalbending.Itmaybenotedthatthebendradiusismeasuredtotheinnersurfaceofthebentpart.

BEND ALLOWANCE

Itisthelengthoftheneutralaxisinthebend,Fig6.1.Thisdeterminestheblanklengthneededforabentpart.Itcan
beapproximatelyestimatedfromtherelation
Lb=a(R+kt)
where,Lb=bendallowance(mm)
a=bendangle(radian)
R=bendradius(mm)

t=thicknessofsheet(mm),and

k=constant,whosevaluemaybetakenas1/3whenR< 2t,andas1/2whenR 2t.

Here,bendradiusR=10mm
Sheetthicknesst=4mm

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Lecture 6

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SinceR>2t,k=0.5
Bendallowance

MINIMUM BEND RADIUS

Astheratioofthebendradiustothethicknessofsheet(R/t)decreases,thetensilestrainontheouterfibresof
sheetincreases.IfR/tdecreasesbeyondacertainlimit,cracksstartappearingonthesurfaceofmaterial.Thislimitis
calledMinimum Bend Radius forthematerial.
Minimumbendradiusisgenerallyexpressedintermsofthethicknessofmaterial,suchas2t,3t,4t,etc.Table6.1
givestheminimumbendradiusallowedfordifferentmaterials.
Table6.1MinimumBendradiusforVariousMaterialsatRoomTemperature
Material

Aluminumalloys

Berylliumcopper

Brass,low-leaded
Magnesium

Soft

Condition

Hard

6t

2t

4t

5t

13t

0.5t

6t

0.7t

3t

Steels

Austeniticstainless

Low-carbon,low-alloy
Titanium

Titaniumalloys

0.5t
2.5t

4t
4t

Bending Force :

There are two general types of die bending : V die bending and wiping die bending. V die bending is used
expensivelyinbrakedieoperationsandstampingdieoperations.Thebendingforcecanbeestimatedfromthefollowing
simplerelation.
P=k.Y.L.t2/D
where P is bending force, g is the yield stress of the material, L is the bend length ( bend allowance ), t is the sheet
thickness,Disthedieopeningandkisaconstantwhosevaluecanbetakenas1.3foraV-dieand0.3forawipingdie.
Fig6.2showsvarioustypesofbendingdies.

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Lecture 6

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Fig 6.2 Die-bendingoperations.

Bendingforcevariesasthepunchprogressesthroughthebendingoperation.Theforceiszerointhebeginning.It
risesandreachesthemaximumvalueasthepunchprogressesandreachesthebottomofthestroke.
Example:

A400mmlongand2.5mmthickpieceofcarbonsteelsheetisrequiredtobebentat900usingaVdie.Youmay
assumetheyieldstressofthematerialas500MPaandthedieopeningas10timesthematerialthickness.Estimatethe
forcerequiredfortheoperation.
Solution:Here,Y=500MPa
L=400mm
t=2.5mm

k=1.3(forVdie)
D=25mm

BendingforceP=k.Y.L.t2/D
=1.3x500x400x(2.5)2/25
=65KN
Example:
Ifthematerialasmentionedintheaboveexampleistobebentat900usingwipingdiewithradius=3.75mm,what
istheforcerequirement?
Solution:Here,Y=500MPa

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Lecture 6

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L=400mm
t=2.5mm
k=0.3

D=2.5+3.75+3.75=10mm(seeFig6.3)

Fig 6.3
BendingforceP=k.Y.L.t2/D
=0.3x500x400x(2.5)2/10
=37.5KN
DRAWING

Itisaprocessofcoldformingaflatblankofsheetmetalintoahollowvesselwithoutmuchwrinkling,trimming,or
fracturing.Theprocessinvolvesforcingthesheetmetalblankintoadiecavitywithapunch.Thepunchexertssufficient
forceandthemetalisdrawnovertheedgeofthedieopeningandintothedie,Fig6.4.Informingacup,however,the
metalgoescompletelyintothedie,Fig6.5.

Fig 6.4 Drawingoperation.

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Lecture 6

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Fig 6.5 Drawingoperation.

Themetalbeingdrawnmustpossessacombinationofductilityandstrengthsothatitdoesnotruptureinthecritical
area(wherethemetalblendsfromthepunchfacetotheverticalportionofthepunch).Themetalinthisareaissubjected
tostressthatoccurswhenthemetalispulledfromtheflatblankintothedie.
OPERATION . Asetupsimilartothatusedforblankingisusedfordrawingwiththedifferencethatthepunchanddieare
given necessary rounding at the corners to permit smooth flow of metal during drawing. The blank of appropriate
dimensionsisplacewithintheguidesonthedieplate.Thepunchdescendsslowlyontheblankandmetalisdrawninto
thedieandtheblankisformedintotheshapeofcupaspunchreachesthebottomofthedie.Whenthecupreachesthe
counterboredportionofthedie,thetopedgeofthecupformedaroundthepunchexpandsabitduetothespring back .
Onthereturnstrokeofthepunch,thecupisstrippedoffthepunchbythiscounterboredportion.

The term shallow drawing is used when the height of cup formed is less than half its diameter. When drawing
deepercup(heightgreaterthatdiameter)thechancesofexcessivewrinkleformationattheedgesofblankincreases.
Topreventthis,ablankholderisnormallyprovided,seeFig6.4.Asthedrawingprocessproceedstheblankholderstops
the blank from increasing in thickness beyond a limit and allows the metal to flow radially. The limiting thickness is
controlledbythegapbetweenthedieandtheblankholder,orbythespringpressureinthecaseofaspringloadedblank
holder.
Somelubricantisgenerallyusedoverthefaceoftheblanktoreducefrictionandhencedrawingload.
Blank Size

Itisgenerallydifficulttofindtheexactsizeoftheblankneededfordrawingagivencup,becauseofthinningand
thickeningofthemetalsheetduringthedrawingoperation.Thefollowingsimplerelationscanbeusedfordeterminethe
blankdiameterD:

whered=outsidediameterofcup
h=heightofcup

r=cornerradiusonpunch.
Drawing Force.

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Lecture 6

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Fordrawingcylindricalshellshavingcircularcrosssection,themaximumdrawingforcePcanbedeterminedfrom
therelation
P=k.t.d.t.Y
whered=outsidediameterofcup
t=thicknessofmaterial

Y=yieldstrengthofmaterial

k=factorwhosevalueisapprox.equalto[D/d0.6]
D=blankdiameter
EMBOSSING

Embossingisanoperationinwhichsheetmetalisdrawntoshallowdepthswithmaleandfemalematchingdies,Fig
6.6.Theoperationiscarriedoutmostlyforthepurposeofstiffeningflatpanels.Theoperationisalsosometimesusedfor
makingdecorationitemslikenumberplatesornameplates,jewelry,etc.

Fig 6.6 Embossingoperationwithtwodies.Letters,numbersanddesignsonsheet-metalpartscanbeproducedbythis

COINING

Coiningisaseveremetalsqueezingoperationinwhichtheflowofmetaloccursonlyatthetoplayersofthematerial
andnotthroughoutthevalues.Theoperationiscarriedoutincloseddiesmainlyforthepurposeofproducingfinedetails
suchasneededinmintingcoins,andmedalorjewelrymaking.Theblankiskeptinthediecavityandpressuresashigh
as five to six times the strength of material are applied. Depending upon the details required to be coined on the part,
morethanonecoiningoperationsmaybeused.
Thedifferencebetweencoiningandembossingisthatthesamedesigniscreatedonbothsidesoftheworkpiecein
embossing(onesidedepressedandtheotherraised),whereasincoiningoperation,adifferentdesigniscreatedoneach
sideofworkpiece.
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