‫بسم هللا الرحمن الرحيم‬

Shearing
Straight blade F=τ ∙ A A=t ∙ L
(parallel blades)
t
Angular blade F=τ ∙ A A=t ∙ L ; L= 2 t g φ
Special die F=τ ∙ A A=t ∙ ∑ L
h
l=
t gφ
h=0.25 ∙t
Rotary cutter A=t ∙
l
y
F=τ ∙ A
(parallel axis) 2 α =cos−1
R
d −h−t
y=
2
Shearing force F=1.3∗τ∗A
(production conditions)
Shearing force by F=
t
∗ξ∗A
beveled edges H
F Shearing force
τ shearing stress
A Shearing sectional area
t sheet thickness
L length of cutting line
𝓵 shearing width
φ upper blade angle
α bit angle
h intersection depth
H beveled edge depth
ξ penetration ratio

Bending
Spread sheet dimensions L=∑ Li + ∑ N i
Bend allowance(arc
length of natural bend N=R ∙ α rad
line)
1 r
z= ; >2
Arc radius of natural R=( r + zt )
2 t
bend line 1 r
z= ; < 2
3 t
π
Bend angle α rad =α ∙ α =180 °−α '
180
b 2
V Bending force F= ∗t ∗σ y ∗n
D
0.7∗b 2
U Bending force F= ∗t ∗σ y w min =r +t
wmin
α
Wanted bend angle α w=
k
t t
The punch nose radius r p =k∗(r + )−
2 2
Minimum bend radius r min =c∗t
die radius r d =r p +1.5 t
t∗E
Maximum bend radius r max =
2∗σ y
L Length of natural bend line
Sum of the straight segments
∑ Li
length
Sum of arcs segments length of
∑ Ni
natural bend line
t Thickness of blank
α' Included angle
r Inside bend radius
w Width of the die opening
σy Yield stress
b Width of blank
n Factor related to the die opening 1.8>n> 1.6
K Spring back constant
E
c Constant related to metal kind
Deep Drawing
Blank diameter D= √ d2 + 4 D( H−0.43 R) A1= A 2
Number of stages needed h q n
q= i
dp
to produce cylindrical cup q <0.75 1
0.75< q<1.5 2
 1.5<q <3 3
3< q<4.5 4
D Rn
q=
D R av
d d n−1
D Rn= n−1 d Pn=
Diameter of punch by d Pn D Rn

steps of drawing D D D
d 1= d 2= d 3=
D R1 D R2 D R3

Maximum load of Load=π . d f .t . σ y (

D
−K ) K=0.6 0.7
drawing df
D 2 −d 2 H n=hn +0.43 r
h n=
4d
Final high of cup t
h n=H n−0.43 R H nf =H n +
2
c l p∧d=t +δ √ L
material First draw redraw
Steel γ =1.08 S
Clearance between the γ =S+ 0.2 √ S
alloy's
die and the punch γ =S+ 0.1 √ S γ =S
Cupper
Aluminu γ =S
γ =S+ 0.05 √ S
m
Abefore = A after
π . D2 π . d2
4
=π . d 1 .h1 +
4
height
Die radius for cylindrical r d =0.8 √ ( d n1−d )∗t
shapes n

R=√r c2 +2 r c h−0.86 r ( r c + 0.16 r)

F dm=t σ y (2 π r c K A + L K B )
hn depth of cup
dp punch diameter
n Number of drawing stage
D Rn Drawing ratio
d n−1
Cup diameter before each
stage of drawing
dn Cup diameter by steps
df Final cup diameter
H High of cup on natural line
c l p∧d
Clearance between the die and
the punch
δ Constant according to the table
 K=0.6 0.7
constant take into
consideration the friction

Ab
σ a=Y m . ln
Aa ( )
Aa
r max =1−
Ab
Ab
[
σ r=Y m 0.8+ 1.5 ln
( )]
Aa

[
σ r=Y m 0.8+ 1.5 ln ( 1−r1 )]
Aa =∑ A
Ab =π . Rb2

Rolling
Value formula Flow of material is constant
Total of thickness ∆ h=h o−hf Q before =Qafter
reduction
The maximum reduction
∆ hmax=μ 2 . R Ab v b= Aa v a
by steps
Length of contact arc L= √ R . ∆ hmax h b w b v b=ha wa v a
F∗L
Torque T= ho Thickness before rolling
2
Power P=F . v=T . ω hf Final Thickness
Liner velocity v=ω∗R ω Angular velocity
 ∆h h o−h f
Number of stages n= = μ Friction factor
∆ hmax ∆ hmax

Friction force F f =μ∗N N Normal force