Chapter 3 Sheet Metal Forming

Manufacturing Engineering Technology in SI Units, 6th Edition
Sheet-Metal Forming Processes and Equipment
Copyright © 2010 Pearson Education South Asia Pte Ltd

Chapter Outline
1. Introduction
2. Shearing
3. Sheet-metal Characteristics and Formability
4. Formability Tests for Sheet Metals
5. Bending Sheets, Plates, and Tubes
6. Miscellaneous Bending and Related Operations
7. Deep Drawing
8. Rubber Forming and Hydroforming
9. Spinning
10. Superplastic Forming
11. Specialized Forming Processes
12. Manufacturing of Metal Honeycomb Structures
13. Design Considerations in Sheet-metal Forming
14. Equipment for Sheetmetal Forming
15. Economics of Sheetforming Operations Copyright © 2010 Pearson Education South Asia Pte Ltd
Introduction
 Products made of sheet metals are common
 Pressworking or press forming is used for
general sheet-forming operations, as they are
performed on presses using a set of dies

Introduction
 A sheet-metal part produced in presses is called a
stamping
 Low-carbon steel has low cost and good strength
and formability characteristics
 Manufacturing processes involving sheet metal
are performed at room temperature

Introduction

Shearing
 Before a sheet-metal part is made, a blank is
removed from a large sheet by shearing
 The edges are not smooth and perpendicular to the
plane of the sheet

Shearing
 Processing parameters in shearing are
1. The shape of the punch and die
2. The speed of punching
3. Lubrication
4. The clearance, c, between the punch and the die
 When clearance increases, the zone of
deformation becomes larger and the sheared edge
becomes rougher
 Extent of the deformation zone
depends on the punch speed
 Height, shape, and size of the
burr affect forming operationsCopyright © 2010 Pearson Education South Asia Pte Ltd
Shearing
Punch Force
 Maximum punch force, F, can be estimated from
F = 0.7TL(UTS )
T = sheet thickness
L = total length sheared
UTS = ultimate tensile strength of the material
 Friction between the punch and the workpiece can

increase punch force

Shearing
EXAMPLE 16.1
Calculation of Punch Force
Estimate the force required for punching a 25-mm
diameter hole through a 3.2-mm thick annealed
titanium- alloy Ti-6Al-4V sheet at room temperature.
Solution
UTS for this alloy is 1000 MPa, thus
F = 0.7(32)( )(25)(1000) = 0.18 MN

Shearing: Shearing Operations
 Punching is where the sheared slug is scrap
 Blanking is where the slug is the part to be used and
the rest is scrap
Die Cutting
 Shearing operation consists of:
 Perforating: punching holes in a sheet
 Parting: shearing sheet into pieces
 Notching: removing pieces from the edges
 Lancing: leaving a tab without removing any material

Fine Blanking
 Very smooth and square edges can be produced by
fine blanking
 Fine-blanking process can control small range of
clearances and dimensional tolerances

Slitting
 Shearing operations are through a pair of circular
blades, follow either a straight line, a circular

path, or a curved path

Shearing: Tailor-welded Blanks
 Laser-beam butt welding involves two or more
pieces of sheet metal with different shapes and
thicknesses
 The strips are welded to obtain a locally thicker sheet
and then coiled
 Resulting in:
1. Reduction in scrap
2. Elimination of the need for subsequent spot welding
3. Better control of dimensions
4. Improved productivity
EXAMPLE 16.2
Tailor-welded Sheet Metal for Automotive Applications
 Production of an outer side panel of a car body is by
laser butt welding and stamping

EXAMPLE 16.2
Tailor-welded Sheet Metal for Automotive Applications
 Some of the examples of laser butt-welded and stamped
automotive-body components.

Shearing:
Characteristics and Type of Shearing Dies
Clearance
 Clearance control determine quality of its sheared
edges which influence formability of the sheared

part
 Appropriate clearance depends on:
1. Type of material and temper
2. Thickness and size of the blank
3. Proximity to the edges of other sheared edges
 When sheared edge is rough it can be subjected to a
process called shaving

Shearing:
Punch and Die Shape

 Punch force increases rapidly during shearing
 Location of sheared regions can be controlled by
beveling the punch and die surfaces

Shearing:
Compound Dies
 Operations on the same sheet may be performed
in one stroke with a compound die

 Limited to simple shapes due to:
1. Process is slow
2. Complex dies is more expensive

Shearing:
Progressive Dies
 For high product production rates
 The part shown below is the small round piece
that supports the plastic tip in spray cans

Shearing:
Transfer Dies
 Sheet metal undergoes different operations
arranged along a straight line or a circular path
Tool and Die Materials

 Tool and die materials for shearing are tool steels
and carbides
 Lubrication is needed for reducing tool and die
wear, and improving edge quality

Shearing:
Miscellaneous Methods of Cutting Sheet Metal
 Other methods of cutting sheets

1. Laser-beam cutting
2. Water-jet cutting
3. Cutting with a band saw
4. Friction sawing
5. Flame cutting

Sheet-metal Characteristics and Formability

Elongation
 A specimen subjected to tension undergoes
uniform elongation
 When the load exceeds the UTS, the specimen
begins to neck
Yield-point Elongation
 Yield-point elongation: having both upper and
lower yield points
 Lüder’s bands has elongated depressions on the
surface of the sheet Copyright © 2010 Pearson Education South Asia Pte Ltd
Yield-point Elongation
Anisotropy
 Obtained during the thermo-mechanical processing
 2 types: crystallographic anisotropy and

mechanical fibering Copyright © 2010 Pearson Education South Asia Pte Ltd
Grain Size
 Affects mechanical properties and surface
appearance
 Smaller the grain size, stronger is the metal
Dent Resistance of Sheet Metals

 Dents caused by dynamic forces from moving
objects that hit the sheet metal

 Dynamic yield stress, instead of static yield stress,
should be the significant strength parameter

Formability Tests for Sheet Metals
 Sheet-metal formability is the ability of the sheet metal

to undergo the desired shape change without failure
 Sheet metals may undergo 2 basic modes of deformation:
(1) stretching and (2) drawing
Cupping Tests
 In the Erichsen test, the sheet specimen
is clamped and round punch is forced

into the sheet until a crack appears

Forming-limit Diagrams
 Forming-limit diagrams is to determine the
formability of sheet metals

Forming-limit Diagrams
 To develop a forming-limit diagram, the major and
minor engineering strains are obtained

 Major axis of the ellipse represents the major direction
and magnitude of stretching

 Major strain is the engineering
strain and is always positive

 Minor strain can be positive
or negative
 Curves represent the boundaries
between failure and safe zones Copyright © 2010 Pearson Education South Asia Pte Ltd
Bending Sheets , Plates, and Tubes
 Bending is a common industrial forming operation

 Bending imparts stiffness to the part by increasing
its moment of inertia
 Outer fibers are in tension, while the inner in
compression
 Poisson effect cause the width to be smaller in the
outer region and larger in the inner region

Bending Sheets, Plates, and Tubes
 Approximate bend allowance is Lb =  (R + kT )
 T
 For ideal case, k = 0.5, Lb =   R + 
 2
Minimum Bend Radius
 Engineering strain during bending is
1
e=
(2 R T ) + 1
 Minimum bend radius, R, is

 50 
R = T  − 1
r  Copyright © 2010 Pearson Education South Asia Pte Ltd
Minimum Bend Radius

 Increase the bendability by increase their tensile
reduction of area
 Bendability also depends on the edge condition of the
sheet
 Improve resistance to edge cracking by removing the
cold-worked regions
 Cold rolling results in anisotropy
by preferred orientation or
mechanical fibering
Springback
 Plastic deformation is followed by elastic recovery
when the load is removed, called springback

 Springback can be
3 calculated by
Ri  RY   RY 
= 4 i  − 3 i  + 1
Rf  ET   ET 

Compensation for Springback

 Springback is compensated for by overbending the
part
 One method is stretch bending where the part is
subjected to tension while being bent

kYLT 2
P=
W
Bending Force
 Excluding friction, the maximum bending force, P,
is
P=
(UTS )LT 2
W
Bending Force
 Examples of various bending operations

Miscellaneous Bending and Related
Operations
 Sheet metal or plate can be bent easily with simple
fixtures using a press
 The machine uses long dies in a mechanical /
hydraulic press suitable for small production runs
 Die materials range from hardwood to carbides

Operations
Bending in a Four-slide Machine
 Lateral movements are synchronized with vertical
die movement to form the part into desired shapes
Roll Bending
 Plates are bent using a set of rolls.
 Curvatures can be obtained by adjusting the
distance between the three rolls

Operations
Beading
 Periphery of the sheet metal is bent into the cavity
of a die
 The bead imparts stiffness to the part by increasing
the moment of inertia of that section

Operations
Flanging
 In shrink flanging, the flange is subjected to
compressive hoop stresses and cause the flange

periphery to wrinkle

Operations
Roll Forming
 Also called contour-roll forming or cold-roll forming
 Used for forming continuous lengths of sheet metal and
for large production runs

 Dimensional tolerances, springback, tearing and buckling
of the strip have to be considered

Chapter 3 Sheet Metal Forming

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Chapter 3 Sheet Metal Forming

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Manufacturing Engineering Technology in SI Units, 6th Edition

Sheet-Metal Forming Processes and Equipment

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Friction between the punch and the workpiece can

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Perforating: punching holes in a sheet

 Parting: shearing sheet into pieces

 Notching: removing pieces from the edges

 Lancing: leaving a tab without removing any material

clearances and dimensional tolerances

Copyright © 2010 Pearson Education South Asia Pte Ltd

blades, follow either a straight line, a circular

Copyright © 2010 Pearson Education South Asia Pte Ltd

laser butt welding and stamping

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

edges which influence formability of the sheared

1. Type of material and temper

2. Thickness and size of the blank

3. Proximity to the edges of other sheared edges

 When sheared edge is rough it can be subjected to a

process called shaving

Punch and Die Shape

 Location of sheared regions can be controlled by

beveling the punch and die surfaces

Copyright © 2010 Pearson Education South Asia Pte Ltd

in one stroke with a compound die

2. Complex dies is more expensive

Copyright © 2010 Pearson Education South Asia Pte Ltd

 The part shown below is the small round piece

that supports the plastic tip in spray cans

Copyright © 2010 Pearson Education South Asia Pte Ltd

arranged along a straight line or a circular path

Tool and Die Materials

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Other methods of cutting sheets

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

 2 types: crystallographic anisotropy and

Dent Resistance of Sheet Metals

objects that hit the sheet metal

should be the significant strength parameter

 Sheet-metal formability is the ability of the sheet metal

is clamped and round punch is forced

Copyright © 2010 Pearson Education South Asia Pte Ltd

formability of sheet metals

Copyright © 2010 Pearson Education South Asia Pte Ltd

minor engineering strains are obtained

and magnitude of stretching

strain and is always positive

 Bending is a common industrial forming operation

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Approximate bend allowance is Lb =  (R + kT )

 Minimum bend radius, R, is

Minimum Bend Radius

when the load is removed, called springback

Copyright © 2010 Pearson Education South Asia Pte Ltd

Compensation for Springback

subjected to tension while being bent