TM16 - Sheet Metalworking PDF

SHEET METALWORKING
1. What is Sheet Metalworking ?
2. Cutting Operations
3. Bending Operations
4. Deep Drawing
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2015
Sheet Metalworking Definition
 Cutting and forming operations performed on

relatively thin sheets of metal
 Thickness of sheet metal

from 0.4 mm to 6 mm
 Obtained by rolling
 Sheet metalworking
usually performed as cold
working
Advantages of Sheet Metal Parts
 Low weight, high strength (with structural elements)
 Good dimensional accuracy
 Good surface finish (aesthetic requirements,

aerodynamic performance)
 Relatively low cost
 Economical mass production for large quantities
Materials for Sheet Metal Parts
 Carbon steel (0.06 – 0.15 %C)
 Galvanized steel (zinc coated)
 Stainless steel
 Aluminum alloy
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
 Small and large appliances
 Office furniture
 Computers and office equipment
Basic Types of
Sheet Metal Processes
1. Cutting
 Shearing to separate large sheets
 Blanking to cut part perimeters out of sheet metal
 Punching to make holes in sheet metal
2. Bending
 Straining sheet around a straight axis
3. Drawing
 Forming of sheet into convex or concave shapes
Basic Types of
Sheet Metal Processes
3° step:
bending
2° step:
shearing
1° step:
punching
Galvanized steel
SHEET METALWORKING
4. Deep Drawing
Sheet Metal Cutting
Shearing action performed

between two cutting edges:
a die (fixed) and a punch
(mobile) with a clearance c
Sheet Metal Cutting
 (1) Just before punch contacts work; (2) punch pushes into
work, causing plastic deformation; (3) punch penetrates into
work causing a smooth cut surface; and (4) fracture is
initiated at opposing cutting edges to separate the sheet
Sheet Metal Cutting
If clearance is correct a good quality fracture is obtained (clean

separation)
Sheet Metal Cutting
If clearance is correct a good quality fracture is obtained (clean

separation)
rollover
burnish
fractured zone
burr
Sheet Metal Cutting
Clearance in Sheet Metal Cutting
 Distance between punch cutting edge and die cutting

edge
 Typical values range between 4% and 8% of
sheet thickness
 If too small, it causes double fracture and larger
force
 If too large, metal is deformed between cutting
edges and excessive burr results
Clearance in Sheet Metal Cutting
Too small Too large

Shearing, Blanking, and
Punching
 Three principal operations in cutting sheet metal:
 Shearing
 Blanking
 Punching
Shearing Operation
 (a) Side view of the operation; (b) front view of power

shears equipped with inclined upper cutting blade
Blanking and Punching
 (a) Blanking - sheet metal cutting to separate piece (called a

blank) from surrounding stock, (b) punching - similar to
blanking except cut piece is scrap, called a slug
Analysis of Cutting Operations
 Punch-Die configuration
 Punch and die size
 Cutting force
Punch-Die Configuration
 Components of a punch and die for a blanking operation
 Cutting force
Punch and Die Size
Design rules:
1. Die size determines

blank size Db
2. Punch size
determines hole size
Dh
Punch and Die Size
 For a round blank of diameter D:

 Blanking die diameter Ddie = D
 Blanking punch diameter Dpunch = D - 2c
where c = clearance
 For a round hole of diameter D:
 Hole punch diameter Dpunch = D
 Hole die diameter Ddie = D + 2c
where c = clearance
Angular Clearance
 Purpose: allows slug or blank to drop through die

 Typical values: 0.25 to 1.5 on each side
Die Resharpening
 Cutting force
Cutting Forces
 Important for determining press size
Fmax = S t L
where S = shear strength of metal; t = sheet

thickness, and L = length of cut edge
Example of Blanking Parts
Example of Blanking Parts
Progressive Die
Progressive Die
Progressive Die
Progressive Die
Progressive Die
Progressive Die
Progressive Die
Progressive Die
Progressive Die
Progressive Die
Progressive Die
Three blanks Three punches
Nesting
SHEET METALWORKING
4. Deep Drawing
Sheet Metal Bending
 Straining of sheet metal around a straight axis

 Metal on inside of neutral plane is compressed, metal on
outside of neutral plane is stretched
Types of Sheet Metal Bending
Two types of sheet metal bending:
 V-bending - performed with a V-shaped die
 Edge bending - performed with a cantilever force
V-Bending
 Features:
 V-shaped punch
 V-shaped die
 Application notes:
 Low-medium
production
 V-dies are
simple and low
cost
Edge Bending
 Features:
 Cantilever loads
 Application notes:
 High production
 Pressure pad
required
 Dies are more
complicated and
costly (especially
for angle different
from 90°)
Edge Bending (< 90°)
Analysis of Bending
 Bending allowance
 Springback
 Bending force
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 final
part length = specified dimension
 Problem: to determine the length of neutral axis of
the part before bending Ab
Ab
Bend Allowance Formula
t
α
Ab = 2π ( R + K bat ) R 
360
where Ab = bend allowance;  = bend angle; R=

bend radius; t = sheet thickness; and Kba is factor to
estimate stretching
 If R < 2t, Kba = 0.33
 If R  2t, Kba = 0.50 (no allowance)
Analysis of Bending
 Springback
 Bending force
Springback
 Increasing of bend angle (with respect to the tool

angle) after tool is removed
’ > ’b
 Due to the elastic energy remained in bent part
Springback
 Also increasing the bend radius

 (1) during bending, work is forced to take radius Rt and angle
b' of the bending tool, (2) after punch is removed, work
springs back to R and ‘
 Solution: overbending
Analysis of Bending
 Springback
 Bending force
Bending Force
 Maximum bending force estimated as follows:

K bf TSwt 2
F
D
For V-bending, Kbf = 1.33; for edge bending, Kbf = 0.33

Bending Complex Shapes
Bending Sequence
1
2
4 5
SHEET METALWORKING
4. Deep Drawing
Drawing
 Sheet metal forming to make cup-shaped,

box-shaped, or other complex-curved
 Sheet metal blank is positioned over die cavity and
then punch pushes metal into opening
 Also known as deep drawing (to distinguish it from
wire and bar drawing)
Drawing: Typical Products
Deep Drawing of Cup
 (a) Drawing of
cup-shaped part: (1)
before punch contacts
work, (2) near end of
stroke
 (b) Starting blank and
drawn part
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 is about 10% greater than

stock thickness
Drawing vs Cutting
 Clearance c:
c = 1.1 t (drawing)
c = 0.04 ÷ 0.08 t (cutting)
 Die and punch radii:
large R (drawing)
small R (cutting)
Multiaxial Stresses and Strains
Metal Sheets for Drawing
 Metal sheets for deep drawing must be isotropic
 Obtained by rolling steps made along perpendicular

directions
Importance of Blankholder
wrinkling
Analysis of Deep Drawing
 Drawing ratio, reduction and

thickness-to-diameter ratio
 Deep drawing forces
 Blank size determination
Drawing Ratio DR
 Most easily defined for cylindrical shape (e.g., cup)
Db
DR 
Dp
where Db = blank diameter; and Dp = punch diameter
 Indicates severity of a given drawing operation

 Upper limit: DR  2.0
Reduction r
 Defined for cylindrical shape:

Db  Dp
r
Db
 Value of r should be less than 0.50
Thickness-to-Diameter Ratio
 Thickness of starting blank divided by blank

diameter :
TDR = t / Db
 Desirable for t/Db ratio to be greater than 1%

 As t/Db decreases, tendency for wrinkling
increases
 Drawing ratio, reduction and thickness-to-diameter

ratio
Deep Drawing Forces
 Drawing ratio, reduction and thickness-to-diameter

ratio
Blank Size Determination
 Determination of diameter of the blank Db

 Solve for Db by setting:
blank surface = final product surface
 Assuming negligible thinning of part wall
Deep Drawing Progression
Dp2
Dp1
Dpn
Db

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SHEET METALWORKING

1. What is Sheet Metalworking ?

 Cutting and forming operations performed on

 Thickness of sheet metal

 Low weight, high strength (with structural elements)

 Good dimensional accuracy

 Good surface finish (aesthetic requirements,

 Relatively low cost

 Economical mass production for large quantities

 Carbon steel (0.06 – 0.15 %C)

 Galvanized steel (zinc coated)

 Sheet and plate metal parts for consumer and

1. What is Sheet Metalworking ?

Shearing action performed

If clearance is correct a good quality fracture is obtained (clean

If clearance is correct a good quality fracture is obtained (clean

 Distance between punch cutting edge and die cutting

Too small Too large

 Three principal operations in cutting sheet metal:

 (a) Side view of the operation; (b) front view of power

 (a) Blanking - sheet metal cutting to separate piece (called a

 Punch and die size

 Components of a punch and die for a blanking operation

 Punch and die size

1. Die size determines

 For a round blank of diameter D:

 Purpose: allows slug or blank to drop through die

 Punch and die size

 Important for determining press size

where S = shear strength of metal; t = sheet

Three blanks Three punches

1. What is Sheet Metalworking ?

 Straining of sheet metal around a straight axis

Two types of sheet metal bending:

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

 Edge bending - performed with a cantilever force

 If bend radius is small relative to stock thickness,

where Ab = bend allowance;  = bend angle; R=

 Increasing of bend angle (with respect to the tool

 Also increasing the bend radius

 Maximum bending force estimated as follows:

For V-bending, Kbf = 1.33; for edge bending, Kbf = 0.33

1. What is Sheet Metalworking ?

 Sheet metal forming to make cup-shaped,

 Sides of punch and die separated by a clearance c

where t = stock thickness

 In other words, clearance is about 10% greater than

 Die and punch radii:

 Metal sheets for deep drawing must be isotropic

 Obtained by rolling steps made along perpendicular

 Drawing ratio, reduction and

 Deep drawing forces

 Blank size determination

 Most easily defined for cylindrical shape (e.g., cup)

where Db = blank diameter; and Dp = punch diameter

 Indicates severity of a given drawing operation

 Defined for cylindrical shape:

 Value of r should be less than 0.50

 Thickness of starting blank divided by blank

 Desirable for t/Db ratio to be greater than 1%

 Drawing ratio, reduction and thickness-to-diameter

 Deep drawing forces

 Blank size determination