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Sheet Metal Design1 PDF
Sheet Metal Design1 PDF
DESIGN
Contents
1
2
3
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
5
6
7
8
9
10
11
12
13
14
15
16
Introduction
Metals used in Sheet Metal Working
Gauges
Sheet Metal Forming Processes
Piercing
Blanking
Fine Blanking
Punching
Trimming
Nibbling
Notching
Drawing
Spinning
Bending
Embossing
Coining
Comparison to other forming processes
Die Manufacturing
Progressive die with scrap strip and stamping
Die operations and types
Design calculations
For Blanking and Piercing
Draw Die Designing
Bending Design
Punching Design
Die Construction
Workshop Practice
Safety Guide for Sheet Metal Workers
Introduction
1.
Sheet metal is simply metal formed into thin and flat pieces. It is one of
the fundamental forms used in metalworking, and can be cut and bent into a
variety of different shapes.
2.
are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are
considered plate.
3.
Sheet metal is available as flat pieces or as a coiled strip. The coils are
4.
The thickness of the sheet metal is called its gauge. The gauge of sheet
metal ranges from 30 gauge to about 8 gauge. The higher the gauge, the
thinner the metal is.
5.
There are many different metals that can be made into sheet metal, such
as: Aluminium, brass, copper, steel, tin, nickel and titanium. Sheet metal has
applications in car bodies, airplane wings, medical tables, roofs for building and
many other things.
6. Sheet metal working involves manufacturing articles from sheet metal or
thin sheets, which may be of black iron, galvanized iron, copper or
stainless steel.
7. The articles made of sheet metals are lighter in weight, and are less
expensive. With properly designed shapes and structures, sheet metal
articles are replacing castings and forgings in several engineering
applications.
8. Besides the articles such as funnels, hoppers, cans, pipes, elbows and
boxes, sheet metal products are used for the purpose of covering machines
and other structures in the form of safety guards or facade of attractive
shapes.
9. Since sheet metal working involves forming shapes from flat metal sheets,
the development and drawing of shape of the article in actual size on the
sheet metal is the most important and prime operation of the work. The
5. Black Iron Sheet or uncoated sheet is the cheapest material used for sheet
metal work. Since these sheets carry no protection coatings on their
surfaces, these are likely to corrode quickly. These are, therefore, used for
marking those articles, which are later enameled or painted before use.
Articles like pans, tanks, cabinet works, almirahs and furnitures are
commonly made from black iron sheets.
6. Galvanized Iron Sheets or G.I. sheets are soft iron sheets carrying zinc
coating on their surface to resist corrosion and to add to the aesthetic of
the sheet. Zinc coating in varying thickness is given according to the
Gauge
The sheet metal gauge (sometimes spelled "gage") indicates the standard
thickness of sheet metal for a specific material. As the gauge number
increases, the material thickness decreases.
Sheet metal thickness gauges for steel are based on a weight of 41.82 pounds
per square foot per inch of thickness. This is known as the Manufacturers'
Standard Gage for Sheet Steel. For other materials, such as aluminium and
brass, the thicknesses will be different. Thus, a 10 gauge steel sheet which has
a thickness of 0.1345 inches will weigh 41.82*0.1345 = 5.625 pounds per
square foot.
Examples: 16 ga CRS is 2.5 pounds per square foot. For 18 ga CRS the weight
is 2.0 pounds per square foot and for 20 ga CRS the weight is 1.5 pounds per
square foot.
SHEET
METAL
FORMING
Galvanized
Stainless
Aluminum
Zinc
e
3
0.2391
steel
-
steel
-
0.006
(6.0731)
0.2242
0.008
(5.6947)
0.2092
0.010
(5.3137)
0.1943
0.012
(4.9352)
0.1793
0.1875
0.1443
0.014
(4.5542)
0.1644
0.1681
0.1719
0.1285
0.016
(4.1758)
0.1495
0.1532
0.1563
0.1144
0.018
10
(3.7973)
0.1345
0.1382
0.1406
0.1019
0.020
11
(3.4163)
0.1196
0.1233
0.1250
0.0907
0.024
12
(3.0378)
0.1046
0.1084
0.1094
0.0808
0.028
13
(2.6568)
0.0897
0.0934
0.094
0.072
0.032
14
(2.2784)
0.0747
0.0785
0.0781
0.0641
0.036
15
(1.8974)
0.0673
0.0710
0.07
0.057
0.040
16
(1.7094)
0.0598
0.0635
0.0625
0.0508
0.045
17
(1.5189)
0.0538
0.0575
0.056
0.045
0.050
18
(1.3665)
0.0478
0.0516
0.0500
0.0403
0.055
19
(1.2141)
0.0418
0.0456
0.044
0.036
0.060
20
(1.0617)
0.0359
0.0396
0.0375
0.0320
0.070
21
(0.9119)
0.0329
0.0366
0.034
0.028
0.080
22
(0.8357)
0.0299
0.0336
0.031
0.025
0.090
23
(0.7595)
0.0269
0.0306
0.028
0.023
0.100
24
(0.6833)
0.0239
0.0276
0.025
0.02
0.125
25
(0.6071)
0.0209
0.0247
0.022
0.018
26
(0.5309)
0.0179
0.0217
0.019
0.017
27
(0.4547)
0.0164
0.0202
0.017
0.014
28
(0.4166)
0.0149
0.0187
0.016
0.0126
29
(0.3785)
0.0135
0.0172
0.014
0.0113
30
(0.3429)
0.0120
0.0157
0.013
0.0100
31
(0.3048)
0.0105
0.0142
0.011
0.0089
32
(0.3200)
0.0097
33
(0.2464)
0.0090
34
(0.2286)
0.0082
35
(0.2083)
0.0075
36
(0.1905)
0.0067
37
(0.1702)
0.0064
38
(0.1626)
0.0060
(0.1524)
PROCESSES
PIERCING
1.
Piercing is a shearing process where a punch and die are used to create
2.
The process and machinery are usually the same as that used in
blanking, except that the piece being punched out is scrap in the piercing
process.
3.
failure.
7.
BLANKING
1.
3.
Generally a blanking die may only cut the outside contour of a part, often
1.
clearance between the punch and die, will produce a part that holds close
dimensional tolerances in relationship to the parts edges.
2.
Appearance: Since the part is blanked in one operation, the finish edges
3.
Flatness: Due to the even compression of the blanking process, the end
result is a flat part that may retain a specific level of flatness for additional
manufacturing operations.
FINE BLANKING
1.
2.
tolerances can be held, and usually additional machining steps can be avoided
post-production.
3.
Materials that can be fine blanked include carbon steels, alloy and
stainless steels, as well as soft non ferrous alloys like aluminum, brass or
copper.
Fine blanking presses are similar to other metal stamping presses, but they
have a few critical additional parts. A typical compound fine blanking press
includes a hardened die punch (male), the hardened blanking die (female), and
a guide plate of similar shape/size to the blanking die. The guide plate is the
first applied to the material, impinging the material with a sharp protrusion or
stinger around the perimeter of the die opening. Next a counter pressure is
applied opposite the punch, and finally the die punch forces the material
through the die opening. Since the guide plate holds the material so tightly,
and since the counter pressure is applied, the material is cut in a manner more
like extrusion than typical punching. Mechanical properties of the cut benefit
similarly with a hardened layer at the cut edge from the cold working of the
part. Because the material is so tightly held and controlled in this setup, part
flatness remains very true, distortion is nearly eliminated, and edge burr is
minimal. Clearances between the die and punch are generally around 1% of
the cut material thickness, which typically varies between .5-13mm. Currently
parts as thick as 19mm can be cut using fine blanking. Tolerances between
.0003"-.002" are possible based on material thickness & tensile strength, and
part layout.
With standard compound fine blanking processes, multiple parts can often be
completed in a single operation. Parts can be pierced, partially pierced, offset
(up to 75), embossed, or coined, often in a single operation. Some
combinations may require progressive fine blanking operations, in which
multiple operations are performed at the same pressing station however.
Advantages
production run.
when additional machining cost and time are factored in (between 1000-20000
parts minimum, depending on secondary machining operations).
Disadvantages
operations.
Broaching
Broaching is the process of removing material through the use of multiple
cutting teeth, with each tooth cutting behind the other. A broaching die is often
used to remove material from parts that are too thick for shaving.
Bulging
A bulging die expands the closed end of tube through the use of two types of
bulging dies. Similar to the way a chefs hat bulges out at the top from the
cylindrical band around the chefs head.
Bulging fluid dies: Uses water or oil as a vehicle to expand the part.
Bulging rubber dies: Uses a rubber pad or block under pressure to move the
wall of a workpiece.
PUNCHING
1.
shape through a sheet of metal and into a die to create the desired shape in
the metal.
2.
The shape is formed by pressing the material against a die with a huge
force. The shear forces generated between the material and die separate the
material into the desired shape.
4.
The desired shape is not obtained, however, as burred edges and rough
surfaces are formed. These edges and surfaces must be further processed until
the desired shape is achieved.
5.
F = 0.7tL(UTS)[citation needed]
Where t is the sheet metal thickness, L is the total length sheared
(perimeter of shape), and UTS is the ultimate tensile strength of the
material.
6.
Die and punch shapes affect the punching process. The punch force
increases during the process as the entire thickness of the material is sheared
at once.
7.
reduces the force at the beginning of the stroke. However, beveling a punch
will disort the punched shape because of lateral forces that develop.
8.
will generally slow down the process and are typically more expensive than
other dies.
9.
punching operations and dies are used at different stages of the operation on
the same machine.
10.
drawing, notching, lancing and bending operations are all related to punching.
11. A punch press is a type of machine press used for forming and cutting
material.
12. The punch press can be small and manually operated and hold one
simple Die set, or be very large, CNC operated, and hold a much larger and
complex die set.
13. A Die set consists of a set of (male) punches and (female) dies which,
when pressed together, may form a hole in a workpiece or may deform the
workpiece in some desired manner.
14.
The punches and dies are removable with the punch being temporarily
attached to the end of a ram during the punching process. The ram moves up
and down in a vertically linear motion.
15. Commonly machines are large metal framed equipment having two types
of machine frames. A C type frame or a 'portal' type frame.
16. The C type commonly has the hydraulic ram at the top foremost part to
enable the punching process to be carried out, whereas the portal frame is
much akin to a complete circle with the ram being centred within the frame to
stop frame deflection or distortion.
17.
All punch press machines have a table or bed with brushes or rollers
mounted in the tables to allow the sheet metal workpiece to traverse with low
friction. Brushes are commonly used in production environments where
minimal scratching to the workpiece is required, such as brushed aluminium or
high polished materials.
18.
The main bed of most machines is called the 'Y' Axis with the 'X' Axis
being at right angles to that and allowed to traverse under CNC control.
Dependent on the size of the machine, the beds and the sheet metal workpiece
weight, then the motors required to move these axis tables can vary in size
and power. Older styles of machines used DC motors to move, however with
advances in technology, today's machine mostly use AC brush less motors for
drives.
19.
The process of operation begins with the CNC controller commanding the
20. Once in position, the control initiates the punching sequence and pushes
the ram to Bottom Dead Centre and returns it to Top Dead Centre. The Origins
of BDC and TDC go back to older machines where this was a pitman type press
with a Pneumatic or Hydraulic operated clutch system.
21. On today's machines BDC/TDC does not actually exist but is commonly
used as a term to derive the top and bottom of a stroke of the ram. The Punch
enters the Sheet metal, and pushes it through the die, obtaining the required
shape of the punch and die set. This will form a slug of metal that is collected
underneath the die and ejected to a scrap container. The whole punching
process on modern machines is extremely fast compared to older pitman style
machines and thus gives rise to increased production volumes.
22.
As a metal forming process, the punch press is used for the highest
the sheet workpiece are commonly nested. Machine setters are mostly used to
set up tooling and programming but thereafter once the machine is running an
operator of low skill can oversee its continued operation. Often one operator
will monitor several punch presses simultaneously making this one of the
lowest cost metal manufacturing processes.
25.
environment a 20 ton press is mostly the prevalent machine used today. The
tonnage needed to cut and form the material is well known so sizing tooling for
a specific job is a fairly straightforward task.
26.
Mechanical punch presses fall into two distinct types, depending on the
type of clutch or braking system with which they are equipped. Generally older
presses are "full revolution" presses that require a full revolution of the
flywheel for them to come to a stop. This is because the braking mechanism
depends on a set of raised keys or "dogs" to fall into matching slots to stop the
flywheel. A full revolution clutch can only bring the flywheel to a stop at the
same location- top dead center. Newer presses are often "part revolution"
presses equipped with braking systems identical to the brakes on commercial
trucks. When air is applied, a band-type brake expands and allows the flywheel
to revolve. When the stopping mechanism is applied the air is bled, causing the
clutch or braking system to close, stopping the flywheel in any part of its
rotation.
28.
Hydraulic punch presses, which power the ram with a hydraulic cylinder
rather than a flywheel, and are either valve controlled or valve and feedback
controlled. Valve controlled machines usually allow a one stroke operation
allowing the ram to stroke up and down when commanded.
29.
2.
edges of the part to improve the edges finish or part accuracy operation
performed.
3.
is sheared away from an already blanked part. Its main purpose is to obtain
better dimensional accuracy, but secondary purposes include squaring the
edge and smoothing the edge.
4.
Nibbling:
The nibbling process cuts a contour by producing a series of
overlapping slits or notches.
Notching
The notching process removes material from the edge of the workpiece. A
notching machine is shown in the below fig.
The machine shown above will create 90 degree notches in sheet metal. This
makes it possible to create profiles that can then be bent into three dimensional
shapes (like boxes). Lay the work on the table. The guides can be used to help
orient the part as desired. Pulling on the actuating lever will cut a notch in the
work.
Drawing:
1.
that the drawing operation undergoes severe plastic deformation and the
material of the part extends around the sides.
2.
difference between formed and drawn. The bottom of the cup was formed
while the sides were drawn.
Spinning
1.
Spinning is used to make rocket motor casings, missile nose cones, and
3.
disc or tube of metal is rotated at high speed and formed into an axially
symmetric part using tools.
4.
or using machine tools, such as CNC lathe, when tight tolerances are required.
Metal may be formed into a die to shape the outside diameter or onto a
mandrel to size the inner diameter.
5.
6.
3.
The flat metal disc is spun against the mandrel and a series of sweeping
motions then evenly transforms the disc around the mandrel into the desired
shape. It takes a very skilled workman to correctly shape and finish a hand
spun piece.
Safety considerations
When spinning metal by hand, care must be taken to not touch the spinning
metal with one's hands until the metal edge has been "turned over" (rolled to a
rounded edge so that the bare edge of the metal stock is protected). This is
mentioned specifically because wood turners are accustomed to touching the
spinning wood in the lathes (once it reaches relative smoothness) to monitor
their progress. This practice is very dangerous in metal spinning. Lexan/Clear
plastic lathe shields and guards are recommended.
Mandrels
The mandrel/chuck can be made from wood, steel alloys, or synthetic
materials. The choice of material is dictated by the hardness of the material to
be spun and by how many times the tool is expected to be used.
Cut-off tools
Cutting of the metal is done by hand held cutters, often foot long hollow bars
with tool steel shaped/sharpened files attached. This is dangerous and should
only be done by skilled tradesmen.
In CNC applications, traditional carbide or tool steel cut-off tools are used.[1]
Rotating tools
Some metal spinning tools are allowed to spin on bearings during the forming
process. This reduces friction and heating of the tool, extending tool life and
improving surface finish. Rotating tools may also be coated with thin film of
ceramic to prolong tool life. Rotating tools are commonly used during CNC
metal spinning operations.
Commercially, rollers mounted on the end of levers are generally used to form
the material down to the mandrel in both hand spinning and CNC metal
spinning. Rollers vary in diameter and thickness depending the intended use.
The wider the roller the smoother the surface of the spinning; the thinner
rollers can be used to form smaller radii.[1]
Lathes
Woodworking lathes are often used, although a wilson lathe is the most
common manual spinning lathe for spinning metal by hand. The mandrel
having been formed from wood on the lathe or steel chuck machined on a CNC
lathe previous to mounting on the metal stock. All stock sizing is done prior to
the spinning.
BENDING
Bending is a common technique to process sheet metal. It is usually done by
hand on a box and pan brake, or industrially on a brake press or machine
brake. Typical products that are made like this are boxes such as electrical
enclosures, rectangular ductwork, and some firearm parts such as the receiver
of the AKM AK-47 variant.
Press Brake
Usually Bending has to overcome both tensile stresses as well as compressive
stresses. When Bending is done, the residual stresses make it re bend or spring
back towards its original position, so we have to overbend the sheet metal
keeping in mind the residual stresses.
The bending
EMBOSSING
1.
the paper.
3.
This is achieved by using a metal die (female) usually made of brass and
a counter die (male) that fit together and actually squeeze the fibers of the
substrate.
4.
This pressure and a combination of heat actually "irons" while raising the
level of the image higher than the substrate to make it smooth. In printing this
is accomplished on a letterpress. The most common machines are the Kluge
Letterpress and the Heidelberg Letterpress.
5.
better finished products as sanitary napkins, diapers, tissue paper and others.
7.
with ink called colour register embossing or with no ink called blind embossing.
8.
It also can be used with foil stamping which when embossed with foil is
All of these processes use a die and counter die. Most types of paper and
Notary use: A notary public frequently uses embossing to mark legal papers,
either in the form of an adhesive seal, or using a clamp-like embossing device
used to certify (a signature on a document, contract, etc.) or cause to become
certified through a notary public or bill.
Postage stamps: Embossing has been used regularly on postage stamps.
Notable early examples include some of the earliest stamps of Italy, Natal,
and Switzerland, as well as the early high values of Britain. Modern stamps
still sometimes use embossing as a design element.
Rubber stamp embossing / Heat embossing: Rubber stamp embossing is
another form of embossing popular in scrap booking and card making. A
rubber stamp is used to apply adhesive (often a slow-drying, sticky ink called
pigment ink) to paper in a desired pattern. Embossing powder is dusted onto
the paper and then blown away, so that it adheres only to the stamped
surface. The powder is then subjected to heat, which causes it to melt and
cover the stamped area. When the heat is removed, the liquified powder fuses
into a palpable smooth raised surface in the shape of the stamped pattern.
Embossing powders are available in transparent, translucent, opaque, metallic,
and glitter colors for a variety of artistic effects.
11.
area of paper is covered with pigment ink and embossing powder sprinkled all
over it and heated until molten. This is repeated so that there are a minimum
of 3 layers of heated powder. While this triple layer of powder is still hot, a
rubber stamp can be pressed into it to leave an indented design.
Embossing also refers to an image processing technique which the color at a
given location of the filtered image corresponds to rate of color change at that
location in the original image. Applying an embossing filter to an image often
results in an image resembling a paper or metal embossing of the original
image, hence the name.
COINING
1.
Coining is similar to forming with the main difference being that a coining
die may form completely different features on either face of the blank, these
features being transferred from the face of the punch or die respectively.
2.
The coining die and punch flow the metal by squeezing the blank within a
confined area, instead of bending the blank. For example: an Olympic medal
that was formed from a coining die may have a flat surface on the back and a
raised feature on the front. If the medal was formed (or embossed), the surface
on the back would be the reverse image of the front.
Compound operations
1.
operation is the act of implementing more than one operation during the press
cycle.
2.
Compound die: A type of die that has the die block (matrix) mounted on
a punch plate with perforators in the upper die with the inner punch mounted
in the lower
3.
set. An inverted type of blanking die that punches upwards, leaving the
part sitting on the lower punch (after being shed from the upper matrix on the
press return stroke) instead of blanking the part through.
4.
A compound die allows the cutting of internal and external part features
variable cost.
4.
5.
Advantages
These are several benefits of spinning and shear forming. Several operations
can be performed in one set-up.
Work pieces may have re-entrant profiles and the profile in relation to
Die (manufacturing)
A die is a specialized tool used in manufacturing industries to cut, shape
and form a wide variety of products and components. Like molds and
templates, dies are generally customized and uniquely matched to the
product they are used to create. Products made with dies range from simple
paper clips to complex pieces used in advanced technology.
Die forming
Forming dies are typically made by tool and die makers and put into
2.
The die is a metal block that is used for forming materials like sheet
metal and plastic. For the vacuum forming of plastic sheet only a single
form is used, typically to form transparent plastic containers (called blister
packs) for merchandise.
3.
4.
For the forming of sheet metal, such as automobile body parts, two
parts may be used, one, called the punch, performs the stretching, bending,
and/or blanking operation, while another part, called the die block, securely
clamps the workpiece and provides similar, stretching, bending, and/or
blanking operation.
5.
The workpiece may pass through several stages using different tools or
operation after the main forming is done and then additional crimping or rolling
operations to ensure that all sharp edges are hidden and to add rigidity to the
panel.
Die components
Die block
Punch plate
Blank punch
Pierce punch
Stripper plate
Pilot
Dowel Pin
Back gage
Finger stop
DESIGN CALCULATIONS
For Blanking and Piercing
Clearances:
Clearances are one of the main factors controlling a shearing process. The
clearance per side is given by
C=0.0032. t .
Where
t= thickness and
= material shear stress, MPa
Clearance as percentage of stock thickness
Material
Round
Other contours
Soft aluminum<1 mm
Soft aluminum>1mm
Hard aluminum
4 to 6
5 to 8
5 to 6
Hard steel
Silicon steel
4 to 5
Stainless steel
4 to 6
5 to 8
Angular Clearance
Angular clearance or draft in a shearing operation depends on the material,
thickness and shape of the stock used.
Its value ranges from 0.25 to 2 deg per side.
Stripper Force:
As the punching is completed the stock tends to grip the punch as the punch
moves upward which makes the use of a stripper necessary to separate the
punch from the job.
The force required for the same is called stripper force
F(s) =K. L. t
Where
F(s) = stripping force, kN
L
= perimeter of cut, mm
= material thickness
=stripping constant
=.0103 for low carbon steels with t<1.5mm with cut at the edge.
=.0145 for same material but for other cuts
=.0207 for low carbon steels, t>1.5mm
=.0241 for harder materials
Punching Force:
As the name indicates it is the force of the punch needed to cut the blank or
pierce a sheet
F(p) = L . t .
F(p)= punching force, N
F(sh)=L.t. (p/t1)
Where,
p= penetration of punch in fractions
t1=shear on punch or die, mm
Draw Radius:
Larger radius causes the metal to be released early by the blank holder and
thus lead to edge wrinkling. Too small a radius causes the thinning and tearing
of the side walls of the cups, generally,
Draw radius=4.t normal
=6 to 8 t when the blank holder is used.
Clearences:
An allowance in the range of 7 to 20% of the blank thickness is provided,
depending on the cup material and cup dimensions.
Clearences in drawing in terms of blank thickness
Blank thickness
First draw
Second draw
Sizing draw
Up to 0.40
1.07 to 1.09
1.08 to 1.10
1.04 to 1.05
0.41 to 1.25
1.08 to 1.10
1.09 to 1.12
1.05 to 1.06
1.30 to 3.0
1.10 to 1.12
1.12 to 1.14
1.07 to 1.09
Above 3.01
1.12 to 1.14
1.15 to 1.20
1.08 to 1.11
(mm)
Blank Size:
The calculation could be based on volume, surface area or by layout. Some
useful relations in calculating the blank diameter for cylindrical shell for
relatively thin materials are given by:
D=(d2+4dh)
when d 20r
D=(d2+4dh-0.5r)
D=(d2+4dh-r)
when 10rd15r
D=((d-2r)2+4d(h-r)+2r(d-0.7r))
Where
r = corner radius of the punch, mm
when d<10r
Drawing Force:
Drawing force for cylindrical shapes can be given by the below empirical
equation
P= dts[(D/d)-C]
Where
P= drawing force, N
t= thickness of the blank material, mm
s= yield strength of the metal, MPa
C= constant to cover friction and bending, its value is 0.6 to 0.7.
For other shapes the above formula gives an approximation which can be used
as a guide.
Ironing force,
In ironing the objective is to reduce the wall thickness of the cup, and hence no
blank is required because the punch is fitted closely inside the cup. Neglecting
the friction and shape of the die, the ironing force can be estimated by the
following equation.
F= d1t1savloge(t0/t1)
Where
F = ironing force, N
d1 = mean diameter of the shell after ironing
t1 = thickness of shell after ironing
t0= thickness of the shell before ironing
sav = average of tensile strength before and after ironing.
Percent Reduction:
There is a limit upto which a material can be strained. The amount of straining
or drawability is represented by the percentage reduction which is expressed in
terms of the diameter of the blank and the shell.
It is convenient to use outer diameter as the cup is normally specified by outer
diameter. The percentage reduction P is given by
P=100[1-(d/D)]
However, practically it is limited upto 40.
Height to
No. of
Percent reduction
dia ratio
draws
First draw
Second
Third
Fourth
draw
draw
draw
Up to 0.75
40
0.75 to 1.50
40
25
1.50 to 3.00
40
25
15
3.00 to 4.50
40
25
15
10
Materials
Percent reduction
Almunium alloys
45
Copper
45
Brass, Bronze
50
45
Stainless steel
50
Zinc
40
Air Vent:
An air vent is normally provided on the punch to reduce the possibility of
formation of vaccum in the cups when it is stripped from the punch. The size of
the air vent depends on the punch diameter
Up to 50
4.5
50 to 100
6.0
100 to 200
7.5
Over 200
10.0
Drawing Speed :
The speed with which the punch moves through the blank during drawing is
termed as the drawing speed. This is very important parameter in drawing
because the higher speeds are sometimes detrimental. Particularly harder and
less ductile materials are likely to be excessively thinned out due to excessive
drawing speeds.
Material
Aluminium
0.90
Brass
1.0
Copper
0.75
Steel
0.28
Zinc
0.75
Bending:
Bending refers to the operation of deforming a flat sheet around a straight axis
where the neutral plane lies. The nomenclature normally used in bending is
shown in fig. In a bent specimen, since neutral axis remains constant, it is the
required length. Beyond the bend lines, the material is not affected. Hence to
calculate the length required, it is necessary to find out the bend allowance
which is the arc length of the neutral axis between the bend lines.
Often bend allowances are calculated for a sheet metal part and used to make
costly tooling or production parts that require a lot of labor to produce. A scrap
tool or production run can be very costly, much more so that a test piece.
So if you are ever not sure of your developed flat length, make a test piece
(laser, turret or sheared piece) to confirm your development.
One of the easiest ways to make a test piece is to shear a piece to an exact
length, and then form it using the exact process that will be used to create the
part. After the part is formed, the part is measured and compared to the
expected lengths and the bend allowance is adjusted as needed. Often times,
when hard tools are produced, laser cutblanks are used to validate the forming
tools and part development before the cutting tools are completed.
No rule will apply to every case. While most bend developments can be predicted
with ease and will develop correctly, there is no perfectly scientific method for
predicting bend allowance due to the many factors like tooling conditions, actual
vs. planned thickness, forming method and the given part tolerance. Many
companies will develop their bend allowances based on standard formulas,
standard forming practices and historical trial and error.
General Principles
The Neutral Axis does not change.
When developing a flat blank length, there is a length of the part that does not
change.
This length is called the neutral axis. Material on the inside of the neutral axis will
compress, while material on the outside will stretch. Based on the material
thickness,
form radius and forming methods, the ratio of compression to tension in the part
will
change.
A part that is bent over a very sharp radius, when compared to the thickness, will
stretch more on the outside, which means that the neutral axis will lie closer to
the
inside of the bend. A part that is gradually bent will have less outside stretch,
which
means that the neutral axis will lie closer to the center of the part.
bend.
3. Different Bend Types & K-Factors
4. Related Formulas
Radian Formula
When a developed length is calculated in radians, the equation is extremely
simplified
because the radian is the actual arc length, so no additional translation into
angles is
needed as in the standard formula below. In fact, the standard formula is the
radian
formula plus a built in angle conversion from radian measure to (base 360)
degrees,
shown in the Common Formula.
Common Formula
Since is more common to develop a part based on degrees instead of radians,
the bend
allowance formula commonly incorporates the degrees to radians conversion.
Recalling that 360 Degrees = 2Radians, then 1 Degree = 2Radians / 360
To convert the radian formula to work with degrees, we make the substitution
2/360
5. Special Cases
Single Hit Z-Bend
When a z-bend is hit in one hit, the middle panel will stretch more than expected.
This
is because the middle panel is trapped between two v-forms. A typical example
might
be on a .312 deep zee bend with .060 material, which might elongate .010.
Wrapped hems
Wrapped hem developments should be treated with caution. While they will
generally
develop with a .29 k-factor, they are at minimum made with a two hit process
and
subject to a bit more variation. If the part has a reasonable tolerance, then the
risk is
minimized. Often times, a wrapped hem is used as a safety edge or a cosmetic
feature.
Additionally, a wrapped hem will see significant backside thinning which
usually
influences the leg length. Most parts are designed to a nominal outside thickness
and
not this backside thinned out thickness, so this must be accounted for in the
developed length.
Shallow z-bends
When a shallow bend is used, the neutral axis of one bend blends into another
one and
does not completely stay within the form arc. This often means that the
developed
length is only slightly longer than the flat length.
Gusseted Bends
When a part has a gusset in a formed flange, the gusseted area will generally
form
high as the gusset drives material beyond the expected development.
Punch Design:
The choice of the type of the punch and its design depends on the shape and
size of the pierced or blanked contour and the work material. Large cutting
perimeters require punches which are inherently rigid and can be mounted
directly. Smalller size holes require punches which may have to be supported
during the operation, and therefore need to have other mechanisms to join th
punch holder. The punches can be broadly classified as: plain punches, pedestal
punches, and punches mounted on punch plate.
Plain Punches:
These are made of solid tool steel block and are directly mounted to the punch
holder. These punches are joined to the holder by means of dowels and screws.
These must be large enough to provide the necessary space for dowels and
screws as well as the necessary strength to withstand the punching force. The
length and width of these punches should be greater than the height of the
punch. Sometime it may become necessary to have a height of the punch
greater than either length or width. This is when the punch is excessivly long and
the work performed is heavy or unbalanced.
Pedestal punches:
The proportions of the pedestal punches are also similar to that of plain punches.
The length and width of the base should be larger than or equal to the height of
the punch. The flange thickness and the fillet radius are to be liberally provided
to withstand the larger forces coming on the punch.
The fillet radius provided in a pedestal punch reduces the stress concentration,
but to strengthen the joining of the punch to the base.
should have a diameter less than 25 mm. As a rule, all the perforators are
mounted in a punch plate.
If the cutting face is round, then assemblig the punch in any orientation is
possible. But for the punches with other contours some means of preventing the
rotation of the punch is necessary.
Some popular methods of preventing the punch rotation are by means of the
spring loaded ball, and the use of dowel slot of the size of 3 mm in the head of
the punch.
Quill punches:
For piercing very small holes less than 6 mm, it is desirable to provide extra
support to the punch shank by means of a closely fitting quill. Quilled punches
are more expensive if made individually because of the close fitting required
between the quill and the punch sizes. Therefore they are mass produces in
various standard sizes.
Back-up plate
Hardened back-up plates are normally required to be kept between smaller
perforator punches and the punch holder. Because of the smaller area of the
perforators, they have the tendency to dig into the softer punch holder in the
absence of a back-up plate. The back-up plate is about 6 mm thick.
Slug Ejection:
Sometimes, the slug that is punched, clinges to the punch face and comes along
with it during the return stroke. Normally, the die is supposed to restrain the slug
from moving along with the punch, because of the spring back. But in slugs of
very small sizes such as those from thin sheets, the spring back being too small,
the slug is likely to be drawn along by the punch. Hence, means are to be
provided for the ejection of the slug, particularly in small perforator punches.
Die Construction
Screws and Dowels:
Dowels are used for alignment of dies while as the screws keep the intact.the
head of the cap screw should be kept in arecessed hole to eliminate any
projection. The recess should be deeper than the head depth by about 3 mm to
account for the resharpening of the die.
For proper alignment of components only two dowels are required. If the
component is too small, the dowels would only weaken it and the construction
would not offer much resistance to any lateral deflection which may be caused
by the unbalanced side thrust. When the height of the component is deonted as
H is greater than 4 times the dowel diameter,d, it is good practice to relieve the
dowel holes. The relieveing would help in the finishing of the dowel hole
Die Block:
The die block size essentially depends on the workpiece size and stock thickness
and sometimes on blank contour.
Die block thickness for mild steel workpiece
Stock thickness (mm)
Up to 1.5
20 to 25
1.5 to 3.0
25 to 30
3.0 to 4.5
30 to 35
4.5 to 6.0
35 to 40
Over 6.0
40 to 50
Up to 75
20
76 to 250
25
Over 250
30
For softer materials such as non-ferrous alloys, die blocks can be made thinner
and similarily for higher shear strength material they can be made thicker.
A more scientific method is based on the experimental results obtained from a
series of die die tests for breakage under impact loading. The results of which
are given in the below table. First the die thickness is to be selected from this
table which is based on stock thickness and its shear strength.
Die block sizes:
Workpiece thickness (mm)
0.25
0.05
0.50
0.10
0.75
0.14
1.00
0.18
1.25
0.21
1.50
0.24
1.75
0.27
2.00
0.29
2.25
0.31
2.50
0.32
The values gvien in above table are for smaller blanks with cutting perimeters of
less than 50 mm. for those with larger perimeters, a correction factor given in
below table is to be applied to the thickness obtained from above table
Expansion factors for die thickness
Cutting perimeter, (mm)
Expansion factor
Up to 50
1.00
51 to 75
1.25
76 to 150
1.50
151 to 300
1.75
301 to 500
2.00
If the die is properly supported in a die shoe, the thickness can be reduced to a
proportion of as much as 50%. A grinding allowance of 3 to 5 mm is to be added
to the die thickness to account for the necessary die sharpenings during the life
of the die.
WORKSHOP PRACTICE
Aluminium Sheets have now very extensive use in a variety of industries, from
building industry to dairy and milk product industry. Aluminium sheets are used
for roofing, doors andwindow frames, kitchen cabinets, kitchenwares, containers,
milk and dairy industry, electrical appliances and aeroplane bodies. Stainless
Steel Sheets provide very high resistance to corrosion. These now have
superseded brass and aluminium for kitchenwares, dairy equipment, food
processing plants, and chemical plants. Lead Sheets are highly malleable, soft
and have good resistance to acidic corrosion. These are weak in strength and
hence are mostly used as liners for containers of acid tanks and other structures.
Zinc Sheets are used for roofing purpose e.g. CGI sheets or corrugated
galvanized iron sheets. Zinc is also used in making die cast products besides
being mostly used for coating purposes. Now we have a clear idea of the types of
metals used. But this is not sufficient, we need to have the knowledge of the
various kinds of tools for converting these materials into useful products. Here
we can correlate lot many examples discussed earlier.
Hand Tools
Common tools used for sheet metal working include:
Standard Scale
Trammels
Circumference Rule
Prick Punch
Straight Edge
Centre Punch
Steels Square
Hand Snip or Shear
Scriber
Stakes
Semi-circular Protractor
Hammers
Dividers
Hollowing Block
Some of these tools are shown below:
Standard
Scale made of
steel
used
is
for
measuring
dimensions and
for
out profiles or
laying
development of
resembles
with
semi-circular
protractor
used
commonly
in
geometrical drawings. It is made of steel mid is used for marking acid measuring
angles. Dividers are used for marking circles and arcs.Trammels are used for
marking large circles or arcs, which are beyond the scope of dividers. Prick punch
is used for indentation marks. The included angle of punch is 300. Centre punch
is used for marking centres for holes to be drilled.The included angle of a centre
porch is kept 900 Hand Snips or Shears are used for cutting sheet metal to the
required shape and size. When size is large, a snip is called Shear. The snips
may be Straight Snips, Bent Snips and Slitting shears. The straight snips have
straight jaws and are used for cutting along a straight line. The bent snips have
curved blades and are used for cutting along curved lines. The slitting shears
have their lower jaws off-set to allow the metal to pass. The cutoff strip of sheet
creates no problem or abstraction to hand. The shears are used for cutting long
and continuous cuts. Stakes are the gadgets used for bending, seaming or
forming operations carried out on sheet metal. Some commonly used stakes by a
tinsmith are shown m Fig. 8 1(b).
The stakes work as both the supporting tool & the forming tool. Bick iron or beak
hoin slake ts a general purpose tool for straight bending, corner seam closing,
rivetting, etc, 0easing stake with horn has a tapering square horn with grooved
slots at one end mid round horn at the other end. The slots are used for wiring
and heading operations of a horizontal sharp edge and is used for making
straight, shape bends, Square stake ire available in different shapes. A hollow
mandril stake is used for rivetting, seaming and forming operations. Round hard
stake is used for forming or shaping curved surfaces A double seaming stake
with four heads comprises a horizontal bar with a hole at one end in which any of
the four heads may be fitted for carrying out operations of seaming, and
rivetting. Hammers used in tin smithy work are of various types in terms of
shape, size and weight. They have round or square heads to suit forming of
round or square shapes Soft faced hammers are used to avoid damage to sheet
metal. A wooden mallet is an soft hammer. A bumping hammer used for raising
curved shapes and a bossing mallet are two typical hammers used in tin smithy
work.
Different types of stakes used for bending sheet metals Hollowing blocks (or
Swages) are made of hard wood and are made to have curved forms or surfaces
on its top face.It is conveniently used for any hollowing process in which sheet
metal is stretched particularly over a large part of the middle area of the blank.
The purpose of rising is to shrink or reduce the circumference of the blank, in
such a way that the metal is worked up or raised to required form.
Soldering Irons or Soldering Coppers consist of a forged tapered piece of copper
bit joined to air iron rod and a wooden handle mid are available in various shapes
and sizes The soldering iron is heated electrically or by some other external
means such as gas stove, smith furnace or even oxy-acetylene flame.
Sheet Metal Joints
Common types of joints used in sheet metalwork
are shown below
(a) Lap Joint (d) Rivetted Joint
(b) Flush Joint (e) Grooved Joint
(c) Edge Over Joint (f) Double grooved Joint
often
joining
two
pipes to
of
chute or hopper
with
used
for
different
Caution: Check with your doctor before exercising. If you feel discomfort while
exercising, stop immediately!
While you are off work, keep yourself physically ready for returning to work,
whether its the next day or later.
Be Aware
If you experience symptoms, you must change the way you work or the tools you
use. If
you dont change, your symptoms may get worse and may keep you from
working at all.
You may have a problem if you have any of these symptoms:
Constant fatigue
Cold hands
Swelling
Numbness
Tingling
Where?
Back
Hands
Follow your companys ergonomics program and its Injury and Illness
Prevention Program.