Manufacturing Engineering Design

TIE 3220

SHEET METAL FORMING

B.SAREMA (NUST)
SHEET METAL FORMING
 Stamping Process
 Stretch Forming
 Stamping Dies
 Stamping Presses
 Process Planning
 DFM Guidelines for Stamped Parts
Sheet Metal Forming Overview

Shearing
Stamping
t<=6.25mm
Non
Sheet metal shearing
forming
Fabrication
t>6.25mm
Assumed knowledge of process
 Bending
 Wipe forming operations
 Punching
 Drawing
 Stretch Forming
 Spinning
Shearing and non-shearing operations
Stamping Operations
Stamping operations
Stamping Dies
 A stamping die is a collection of parts mounted on a press
used to produce a part.
 All die components or presses are similar
 Most stampings require a series of operations.
 These operations can be carried out using a single die, called
a progressive die, or on compound or combination dies
 Progressive dies are divided into sections (called stations) that
perform multiple operations with each stroke of the press
 The part is carried from station to station by the stock strip
that is left attached to the part throughout the operation until
its cut out at final stage
 A compound or combination die is essentially a single station
die that performs two or more operations (one inside of the
other) with each stroke of the press.
Progressive die

A progressive die uses one press

Progressive die

A progressive die uses one press

Compound die

A compound die uses one press

Stamping Press
Types of Presses
• Mechanical

• Hydraulic

• pneumatic
Stamping operations
 A decision has to be made for use of
progressive die vs compound dies.
 Sometimes secondary presses are required to
make a part
 Where the part cannot remain attached to the
strip, transfer dies are used e.g. Curled edges
on a part
 The cycle time is lower than injection moulding
and die casting (approx. 2.5 s)
 A decision on the operations required and their
sequence has to be made. (Process Planning)
Process Planning
 The actual configuration of the tool depends
on the processing sequence, or processing
plan, to be used to produce the stamped
part.
 There is a relationship between the process
plan and part attributes
 Tooling cost consists of die material cost
and die construction cost.
 Die construction (Engineering cost + the Built
cost)
 Assumption: progressive die is used.
Process Planning
Strip development
 The 1st step in designing a progressive die
is the development of a process plan or
strip layout.
 A strip layout is a visual representation of
the sequence of operations used to form a
part in a progressive die.
Process Planning
Strip development
 Acts as a guide to check whether;
 The die may be too complex to manufacture.
 The operations involved may be too difficult for
a progressive die, hence the use of compound
and secondary dies may be preferred.
 The operations required may be too long or too
wide or require too much tonnage for the
presses available at a particular site
Process Planning
Guidelines to Strip development
 All holes that can be pierced without danger of
dislocation or deformation should be pierced prior
to bending or forming.
 If the part contains holes, uses them as piloting
holes (internal pilots) and should be punched in
the first station.
 When there are no holes available punch external
pilot holes.
 The existence of numerous die stations having
many punches tends to weaken the overall die.
(use idle station when the punches from two
active stations are too close )
Process Planning
Guidelines to Strip development
 For external contour of a part, notching operation
must precede wipe forming or bending.
 Although idle stations are often included to
strengthen a die, at times they are also included
in order to ease die maintenance or to provide
flexibility in the event that additional operations
need to be added later
Process Planning
Guidelines to Strip development
Process Planning
Guidelines to Strip development
Process Planning-alternative strip layouts
Strip development Steps
1. Make a sketch of the unfolded part and enclose
the part in a flat rectangular envelope

2. Make three or four copies of the sketch created in

Step 1 and lay the sketches side-by-side to create
two alternative patterns ( use both orientation)
Strip development Steps
(use both orientation)
Feeding with Lul perpendicular
to the feed seems to make
both notching and bending a
bit easier

This should help to determine

which is the best way to feed the
part, and the number and shape of
the notching punches needed to
create the peripheral shape of
the unfolded part.
Strip development Steps
3. Attach a carrier strip to the pattern and begin to label the
various workstations.
Strip development Steps
4. Start laying out operations
DFM Guidelines for Stamping
 The number of distinct features in a part
should be kept to a minimum.
 Avoid closely spaced features
 The use of narrow cut-outs and narrow
projections should be avoided.
 The number of bend stages in a part
should be kept to a minimum.
 Bend angles greater than 90 ~ should be
avoided whenever possible.
 Side-action features should be avoided or
kept to a minimum.
Narrow projects