WOLAITA SODO UNIVERSITY

COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING

Tool Jig and Die Design project

Group 2

Name ID Number

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Table of Contents
Abstract..................................................................................................................................................i
Introduction...........................................................................................................................................1
Bending..............................................................................................................................................1
Methods of bending..............................................................................................................................1
Induction bending..............................................................................................................................2
Rotary draw bending.........................................................................................................................3
Roll bending.......................................................................................................................................4
Point bending/gag pressing...............................................................................................................5
SYNCHRONIZED INCREMENTAL COLD BENDING................................................................................6
HOT BENDING....................................................................................................................................6
Types of bending...................................................................................................................................8
Air Bending........................................................................................................................................8
Coining...............................................................................................................................................9
Bottom Bending...............................................................................................................................10
How to Prevent Wrinkling During Deep Drawing?...............................................................................11
Causes of Wrinkling in Deep Drawn Parts........................................................................................11
Methods for Preventing Wrinkling in Deep Drawn Parts:................................................................12
Using a Blank Holder........................................................................................................................12
Methods of preventing wrinkling in deep Drawn Parts: Die Cavity Design......................................13
Conclusion...........................................................................................................................................14

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 Abstract

Methods of bending is provided to perform different

type of bending and they are alternative to bend.
Methods bending, types of bending and how to prevent
wrinkles on bending are included in this project. These
methods and types of bending are used to perform
perfect and good bending.

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 Introduction

Bending

Bending is a manufacturing process that produces a

V-shape, U-shape, or channel shape along a straight axis
in ductile materials, most commonly sheet metal.
Commonly used equipment includes box and pan
brakes, brake presses, and other specialized machine
presses.

Methods of bending
There are seven typical methods of bending in the
industry:
1, induction bending
2, rotary-draw/compression bending

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3, roll bending
4, plate rolling
5, point bending / gag pressing
6, synchronized incremental bending
7, hot bending (using induction or other heating
sources).

Some bending methods can be used in conjunction

with one another. For example, you can hot bend
material utilizing an incremental bending process. Each
method has its advantages. Some methods are more
commonly used in the steel construction industry, while
others are more common in the automobile or
manufacturing industries. The seven most widely used
bending processes in the industry are listed below in
greater detail.

Induction bending
 Induction Bending is a controlled means
of bending pipes through the application of local
heating using high frequency induced electrical
power. ... As the correct bending temperature range
is reached, the pipe is moved slowly through
the induction coil whilst the bending force is
applied by a fixed radius arm arrangement.

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Rotary draw bending
 Rotary draw bending is one of the most versatile
and common methods to bend pipe and tube. The
radius of such bends is often described as, for
example, “2D.” A 2D bend is one whose centre-line
radius is equal to two times the outside diameter of
the pipe to be bent.
 Rotary draw bending involves clamping on the
outside diameter of a pipe and drawing it over a form
whose radius matches the desired bend radius.
 Rotary draw bending often employs an internal
supporting mandrel and a wiper die to prevent
wrinkling on the inside wall of a tight bend. Some
rotary draw machines can perform both push
bending and rotary bending with a single tooling
setup.

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Roll bending
 If bending is well-suited to making relatively sharp
radii, then roll bending is ideal if we want to make
larger ones (Figure 4.7). This method allows us to
make a cylindrical product, or even, with the right
kind of control over the rollers, cones. The forces
required to do this are relatively modest, especially
because the deformation is usually obtained
gradually: the blank passes back and forth through
the machine several times, with the rolls being
repositioned after each pass. Because the radii are
large, spring back presents a challenge, as the ratio
of elastic over total deformation energy is relatively
high.

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(a)

Fig: Schematic of roll bending; (b) curved strip and rolled product (pedal bin ).

Point bending/gag pressing

 Gag pressing, also known as point bending or cold
cambering, is a bending method that uses hydraulic
rams to simultaneously apply forces at discrete
locations along the member to produce large-radii
bends. This is the most common method for
cambering beams to offset a portion of the service-
load deflections; therefore, the hydraulic rams are
located approximately at one-third points to produce
a curved shape approximating a typical beam
deflection curve. The supports for most cambering
machines are between 20 and 28 ft apart. Because
beam lines can be used only with straight members,
beams are usually cambered after they are cut to the
final length and holes are punched or drilled. If the
machine capacity is exceeded, heat can be applied to
the member to reduce the yield stress.

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SYNCHRONIZED INCREMENTAL COLD BENDING

 Incremental step bending is a cold-bending method

that uses hydraulic rams to apply bending forces at
several discrete, closely-spaced locations along the
member. Cross-sectional elements can be supported
mechanically or hydraulically to reduce distortion
during the bending operation, resulting in the
potential for small-radius bends with minimal
distortion.

HOT BENDING

 Hot bending is any process where curvature is

induced by load application at an elevated
temperature. Also known as heat-assisted bending,
the primary advantage of hot bending is that the
material yield strength is lowered from the room
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 temperature value, requiring smaller forces to be
exerted by the bending machine. Heat is applied
directly to the member by flame, by heating in a
furnace, or by induction coil, followed by the
application of a bending force. The member can be
bent around present forms, but more often the
bending force is applied using one of the previously
discussed bending methods. For HSS members, the
heat can be applied either externally or internally.
For cambering beams by gag pressing, the
application of heat is typically used only where the
beam strength exceeds the machine capacity.

Types of bending
Air Bending
Air Bending is the most common type of bending
process used in sheet metal shops today. In this process
the work piece is only in contact with the edge of
the Die and the tip of the Punch. The punch is them
forced past the top of the die into the v-opening without
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coming into contact with the bottom of the v. The v
opening is typically deeper than the angle which is
sought in the work piece. This allows for over bending,
compensating for the Spring Back of the work piece.
Typically, 30-degree tooling can be used to fully air bend
and 90- or 88-degree tooling can be used to partially air
bend. There has recently been the introduction of 75
degree tooling to allow for full Air Bending, without the
tooling restrictions of Acute Angle Tooling. (Acute
punches are almost always knife dies with no goose-
neck.) Because the punch tip does not penetrate the
work piece the inside radius of the bend is controlled
almost entirely by the size of the v-opening of the bottom
die. The larger the v-opening the larger the radius will
be. This has both pros and cons, the pros being that the
operator can control the radius of a bend even when
working with the same material and thickness just by
changing the bottom die. This can be used to
compensate for errors in the layout or achieve a wider
variety of design options. This same versatility can work
against you as well as it can lead to bad parts if the
wrong dies are used. Dies should be clearly marked for

their intended gauges. The determination of tooling is

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done with the assistance of an Air Bend Force Chart. A
further note on Air Bending is that it should almost
never be used on older, mechanical, Brake
Presses because of their inherent margin of error, even
the difference of a few thousands of an inch can result in
bad parts.

Coining
Coining is a very basic type of bending in which the
work piece is stamped between the punch and die. The
material is put under enough pressure that the punch
tip penetrates the material and it begins to flow into the
die. This method produces excellent accuracy and
repeatability, and does not require sophisticated
machines to execute. It does however very large
tonnages compared to Air Bending. Often times in
excess of 50 tons per inch of material, compared to 1 or 2
tons per inch for Air Bending. Because of these
tonnage requirements wear and tear on the machines
will be much greater than air or Bottom Bending.
Tooling required for Coining must be robust and this can
limit your tooling and geometry options. Because of the
tooling restrictions and the large tonnages required to
coin this process is rare in the press brake world.

Bottom Bending

Bottom Bending has similarities to both Air Bending

and Coining. In this process the die angle should match
the intended angle of the work piece, adjusting a few
degrees for Spring Back, hence the existence of 88-
degree tooling to achieve 90-degree angles. The work
piece is first bottomed against the die, then the radius of
the punch is forced into the work piece which achieves
the angle of the punch, it is then released and the work
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piece springs back to meet the die again. Unlike Coining
however, the material is not under so much tonnage that
the metal flows. Because of this there is still Spring
Back which must be compensated for. In order to do
compensate the angle of the punch can be smaller than
the angle of the die should not be larger or else you will
damage the tooling. This method can give an operator
excellent repeatability if properly set up. Setting up a
Bottom Bending operation accurately requires knowledge
in the tooling, material, tonnages and even the timing of
the different steps so it lends itself by a few degrees
allowing an over-bend when the punch tip is forced into
the work piece, it to a more skilled operator.

How to Prevent Wrinkling During

Deep Drawing?

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 In the deep drawing process, a punch pushes a sheet metal blank
into a die cavity, resulting in a contoured part. A part is said to be
deep-drawn if the depth of the part is at least half of its diameter.
Otherwise, it is simply called general stamping.

Causes of Wrinkling in Deep Drawn Parts

Several factors can cause wrinkles in deep drawn parts,

including:

 Blank holder pressure

 Die cavity depth and radius
 Friction between the blank, blank holder, punch and
die cavity
 Clearances between the blank, blank holder, punch
and die cavity
 Blank shape and thickness
 Final part geometry
 Punch speed

Methods for Preventing Wrinkling in Deep Drawn Parts:

Using a Blank Holder

The simplest method for eliminating wrinkling in deep-

drawn parts is using a blank holder. In most deep
drawing processes, a constant blank holder pressure is
applied throughout the entire drawing action.

Variable blank holder pressure, however, has been

employed with some success. A pneumatic or hydraulic
blank holder cushion can vary the blank holder pressure
linearly over the stroke of the machine. This provides
some increase in the allowable die cavity depth.

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A numerically controlled (NC) die cushion can be used to
provide a variable blank holder pressure over the course
of drawing action. In an optimal blank holder pressure
force profile, the initial force is large so as to provide
initial deformations.

The cushion drops off to pull material into the die cavity,
and then slowly increases back up to ensure strain
hardening in the drawn part. An NC die cushion can
dramatically increase the allowable die cavity depth while
preventing both wrinkling and cracking.

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Methods of preventing wrinkling in deep Drawn Parts: Die
Cavity Design

The design of the punch and die cavity can be optimized

to reduce the probability of wrinkling. Choosing a flange
radius that is just large enough to prevent cracking can
minimize the potential for wrinkles. Additionally,
considering minimizing the part complexity and any
asymmetry can also help. Incorporating a multi-step
drawing process offers a variety of advantages in
preventing wrinkling in deep-drawn parts.

Designing the blank geometry to minimize excess

material can reduce the potential for wrinkling. The sheet
metal blank has an inherent grain structure, so the
stresses can vary depending on the design of the die and
the orientation of the grain. Adjusting the grain in an
asymmetrical design to minimize the compound of grain
stresses and the general stresses of the deep draw
process is something to take into consideration.

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Conclusion
Bending is a process of curving of metal rod or metal
sheet in manufacturing process. There are several
methods of bending and type of bending.

Due to some different factor wrinkles are formed on the

bending material. To perform a good bending the
operator must be prevent wrinkles.

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