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Sheet Metworking 1
Sheet Metworking 1
IME 240/340
TABLE 16.2
Characteristic
Elongation
Yield-point elongation
Anisotropy (planar)
Anisotropy (normal)
Grain size
Residual stresses
Springback
Wrinkling
Quality of sheared edges
Formability
Formability is the ability of sheet metal to undergo shape
change without failure by necking
(a)
or tearing
Cupping (Swift or Ericson) tests give
some idea of formability
(a) Yield-point elongation in a sheet-metal specimen. (b) Lueder's
bands in a low-carbon steel sheet. Source: Courtesy of Caterpillar Inc.
(c) Stretcher strains at the bottom of a steel can for household products.
(a)
(b)
(c)
Shearing
A blank is a properly sized piece
of sheet metal removed from a
much larger sheet or coil by
shearing
Shearing is cutting by subjecting
a workpiece to shear stresses
Shearing starts with small cracks
at points A, B, C, D which
eventually grow and meet
Rough fracture surfaces and
smooth burnished surfaces result
Shear angles or beveled edges
often used on shearing dies
(a) Schematic illustration of shearing with a punch and die, indicating
some of the process variables. Characteristic features of (b) a punched
hole and (c) the slug. Note that the scales of the two figures are different.
Shearing Parameters
Clearance, c, between the punch and die typically
between 2% and 10% of sheet metal thickness
As clearance increases, sheared edge becomes rougher
and zone of deformation becomes larger clearances are
smaller for softer metals, thinner sheets, or larger holes
Ratio of burnished to rough edges increases with:
increasing ductility, decreasing clearance and thickness
Faster punch speeds cause narrower sheared zones and
less burr formation
Burr height increases with increasing clearance, ductility,
or dull tools
Maximum Punch Force, F = 0.7 T L (UTS)
(product of thickness, sheared edge perimeter, and UTS)
Shearing Operations
Punching sheared slug is discarded
Blanking slug is workpiece, surrounding area discarded
Die cutting includes perforating (many holes), parting
(separating into multiple pieces), notching (removing
pieces from the edges), and lancing (leaving a tab)
Fine blanking with 1% clearances produces very smooth
and squared off edges
(a)
(b)
(a) Comparison of sheared edges produced by conventional (left) and by fine-blanking (right) techniques.
(b) Schematic illustration of one setup for fine blanking. Source: Feintool U.S. Operations.
Shearing Operations
Slitting cutting off with 2 circular blades (can opener)
Steel rules a die for shearing soft metals, paper, leather,
and rubber into specific shapes (cookie cutter)
Nibbling reciprocating die for successive, overlapping
holes that shears intricate, flexible shapes
Shaving trims excess material to clean sheared edges
Compound and progressive dies perform several operations
Slitting with
rotary knives.
Shaving and
compound dies
Laser Cutting
Cut-Off Die
Part-Off Die
Blanking Die
Multi-stage Stamping
Progressive Die
*
*
*
Reducing Scrap
Scrap metal can be as high as 30%
Computer aided design and planning can minimize scrap
Tailor-welded blanks are multiple pieces of flat sheet buttwelded together and simultaneously stamped
Production of an outer
side panel of a car body,
by laser butt-welding
and stamping. Source:
After M. Geiger and T.
Nakagawa.
Turret Presswork
Turret of
standard tools
Ri
RiY
RiY
4
3
1
Rf
ET
ET
kYLT 2
P
W
(UTS ) LT 2
P
W
For a V-die
Springback Reduction
2R T 1
(a)
R T 50
r 1
(b)
(a) and (b) The effect of elongated inclusions (stringers) on cracking, as a function of the direction of
bending with respect to the original rolling direction of the sheet.
Roll Forming
Multi-stage rolling process for producing elongated
sectional products from sheet metal
Typical products are rain gutters and down spouts
Competes with extrusion for some products
Drawing Parameters
Wrinkling is caused by compressive (hoop) stresses that
are induced as the blank moves into the die cavity
Blankholder (or hold-down ring) pressure must be correct
Too much pressure causes tearing, too little causes wrinkling
Typically 0.7-1.0% of the sum of the UTS and yield strength
If Do-Dp < 5T, deep drawing may
be successfully achieved without
a blankholder
Drawing Parameters
PunchDiameter
Dp
Normal anisotropy
w
WidthStrai n
R
ThicknessStrain t
R for rolled sheet metal
Ravg
R0 2 R45 R90
Drawing Parameters
Redrawing
Forward redrawing
Ironing
Elongates and thins walls of
the cup
Deep
Drawing
Products:
pots, food
and
beverage
containers,
kitchen
sinks, car
fuel tanks
Stretch Forming
Sheet metal is clamped at edges and stretched over a die
or form block
Dies made of zinc alloys, steels, plastics, wood
Little or no lubrication
Low-volume, versatile, and economic production
Products:
aircraft wing
skin panels,
automobile
door panels,
window
frames
Source: Cyril Bath Co.
Metal Spinning
Metal Spinning
p is pressure in psi
K is a constant (21600 for TNT)
W is weight of explosive (lbs)
R distance of explosive from workpiece
a is a constant (generally 1.15)
p K