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SHEET METAL
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What is Sheet Metal?

Characterized by a high ratio of surface area to thickness.
Material thickness lesser than 6 mm ( ~ in).
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Content
Application
Material
Sheet Metal Cutting
Sheet Metal Forming
Sheet Metal Drawing
Bend Allowance
K Factor
Stress Relief Cuts
Spring Back
Grain Direction
End Condition
Min Flange Width
Holes / Slots
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Application

For appearance / Aesthetic
Strengthen the part and add rigidity
To aid in assembly
For functional purposes

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Sheet Metal Cutting

Why?
To Generate Sheet Metal Strips.
To generate Blanks.
To generate Sheet Metal parts.

Concept

Shear force applied by punch and die.
When shear stress greater than shear strength metal cutting starts.


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CUTTING OPERATIONS
Producing Blanks Cutting Holes
Shearing
Cutoff
Parting
Blanking
Punching
Slotting
Perforating

Progressive Working Miscellaneous
Notching
Semi-Notching
Lancing
Trimming
Slitting
Shaving

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Producing Blanks

BLANK - Definition


When sheet metal is cut from strip and the piece
becomes the part or product being manufactured is called as
blank


Note :
In some cases the blank is the complete product.
In other cases blank is formed or drawn to produce final part.
Both cases may or may not require additional metal working.
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SHEARING










The cutting action must be along a straight line.
Sheet metal sheared off may or may not be called a blank.
No Die is used.
So shearing is not a stamping process.
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CUTOFF
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CUTOFF


Cutting action need not be an straight line.
May be curved, angular or broken.
But resulting pieces are called as blank.
Dies are used. So stamping process.
Nesting is an important factor.
No Scrap Material.
Scrap may be at starting or end which are negligible.
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PARTING





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PARTING










Another category of cutting operation.
Scrap material is unavoidable.
Alternate blank produces scrap.
Not a efficient like shearing and Cutoff.
Next best method for creating blank if properly nested
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BLANKING
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BLANKING





Cutting action must be about the complete contour. .
Excessive scrap is formed during blanking.
Inefficient process for cutting blanks.
Dies are used. So stamping process..
Resulted scraps are called as Skeleton
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Cutting Holes




Cutting operation is done on the blank or on the part being
manufactured part.
Some time on Scrap too to position the sheet metal
correctly in the die.

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PUNCHING







Definition
When the hole is cut on blank or product manufactured is
called as punching.

Size and number of holes are unlimited as long as they are
in the same part.
Holes may be punched in the scrap area.
Scraps produced by punching is called slugs.
Punching is a stamping process.
Piercing also produces hole but it is different from punching.
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SLOTTING








Punching and slotting are similar operation.
Properties are same for both.
Main difference is slotting refers to the cutting of elongated
or rectangular holes.
Slotting is done only on blank or part.
Rare to see slotting on scrap metal.
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PERFORATING









Group of punched or slotted holes.
Holes may be cut simultaneously or in progressive stages.
In general holes are equally spaced or in a definite pattern.
Perforating is usually performed in die; therefore, it is a
stamping operation.
Perforated holes need not be in same shape and size.

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Progressive working







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NOTCHING
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NOTCHING





Cutting operation during which the punch does not cut
on all sides.
Notching removes piece of scrap metal from the edge of
strip or blank.
Scarp is a compulsory product of notching.
Notching is a stamping operation.

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Notching Where used?

To free sheet metal for drawing while still attached to the
strip.
To free sheet metal for forming while still attached to the
strip.
To remove excess metal for drawing or bending.

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SEMI-NOTCHING
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SEMI-NOTCHING






Has the same purpose as notching, in that it is used to free
metal for drawing or forming.
Metal is cut about closed contour.
No metal is removed from the edges.
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LANCING












Cut is made a part way across the metal.
No scrap is produced.
In general this is done for local bending.
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TRIMMING
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TRIMMING





During drawing the outer end has to be gripped.
This process is done after drawing process.
This action prevents the flow of material into die and avoids
wrinkling of the metal.

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SLITTING
















Coil is cut into several coils.
This is performed in special machines.
So not as an stamping process.
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SHAVING















Cutting metal in chip fashion rather than plastic deformation
and fracture.
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Sheet Metal Forming
Why?
To strengthen the part and add rigidity.
For appearance or sales appeal.
To remove sharp edges produced during cutting operations.
To aid in assembly.
For functional purposes.



Forming operations have the characteristic localized
stressing with tension on the outside and compression on the
inside of the formed area. .


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FORMING OPERATIONS
FORMING
Bending
Flanging
Hemming
Seaming
Curling
Wiring
Ribbing
Staking
Crimping
Bulging
Corrugating
Beading
Embossing
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BENDING
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BENDING




Bending is the plastic deformation of metals about the
bending axis with little or no change in the surface area.
Bend axes are linear and independent.
Independence means that bending about one axis has no
effect on the bending about the other axis
The bending process is used not only to form parts such as
angle sections, flanges, seams, and corrugations.
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FLANGING



Area formed down is small in relation to the remainder of
the part.

Why Flanging,

To strengthen the edges.
To add rigidity.
To remove sharp edges.
To remove burrs.
To aid the assembly of two parts.
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Types of Flanges,

Straight
Stretch
Shrink
Reverse
Jogged
Hole
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STRAIGHT FLANGE














Straight flange is least severe on the metal.
Stress is created only on the bend area.
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STRETCH FLANGE













Stretch flange causes excessive amount of tension is placed
on the metal.
Tearing and breaking of metal would be most common in the
stretch flange.
Control of clearance and forming details must be precise.
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REVERSE FLANGE













Reverse is combination of both stretch and shrink.
It includes the advantage as well as disadvantages.
Only part shape demands this method has to be adopted.
Reversal of stress involved and causes breaks and wrinkles.

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JOGGED FLANGE














Jogged flange consists of straight flange that is offset at one
point.
Only part shape demands this method has to be adopted.
Reversal of stress involved and causes breaks and wrinkles.
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HOLE FLANGE














Hole flange involves tensile stresses.
Higher the flange higher the tendency of breaking.
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HEMMING









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HEMMING

Hem is a fold at the edge of the material to remove the
ragged edge and improve the appearance of the edge.
Adds slightly to the rigidity of the edge and improves wear
resistance.
Plain hem strengthen the edge of sheet metal in a manner
similar to flange.
Improves rigidity.
This is not used on the flanges.
This produces smooth edge. Normally on the thin sheets
Single hem and partially flanged part together forms assembly
hem. Often this strength is sufficient.
Some time spot weld/rivet or join operation is done.
Assembly hem keeps correct relationship between the parts
and gives more strength to the assembly.
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SEAMING












Another term is double hem.
Two hems joined in such a way to assemble two sheets. Has
sufficient strength to be used as is.
Sometimes the lock seam is soldered or filled with cement
to get leak proof.
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WIRING












Wiring is used to strengthen the edge of sheet metal.
Rigidity is improved.
Metal is curled up over a length of wire.
Edge is strengthened by both the wire as well as curl formed
in the metal.
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CURLING











Curling is used to strengthen the edge of sheet metal.
Rigidity is improved.
Edges are simply curled with out wire.
This is also called as false wiring.
By curling two different sheets assembly can be formed.
Leak proof is ensured by cement or solder.
Assembly has high rigidity and strength.
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RIBBING
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RIBBING




When one sheet is bent or flanged the rigidity is still not
sufficient.
To increase rigidity ribs are formed between the flange or
bend and the remaining part.
In plain part both directions have to be taken care to add
rigidity.
In circular part it is called as Bead.
Care must be taken in ribbing other wise metal will fail since
ribbing is a stretching operation.
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STACKING



This is primarily for assembly purposes.
Staking is performed either at the edge or in the central
section of the parts to be joined.
In general all staking operations are performed in Die.


Types,

Edge stake
Center stake
Tab stake
Upset stake
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Types of Stacking
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CRIMPING
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CRIMPING




This operation is used mainly for assembly purpose.
Bottle caps are best example for this.
The force exerted by the crimped cap is sufficient to
withstand the pressure of liquid inside.
Electric wiring assembly is another best example.
When wood is assembled to metal crimping is adopted.
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BULGING













Rework on drawn cups into other contours.
Bulging expands the cup along the narrow band and at the
same time reduces the height of the cup.
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CORRUGATTING












To add stiffness and rigidity this operation is done
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BEADING













This is used to stiffen round parts in a manner similar to rib.
Beads are forced in the circumference of round barrels or
drums to add rigidity.
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EMBOSSING










Embossing involves displacing of metal without noticeable
reduction in sheet metal thickness.
Embossing is visible from the other side of sheet.
This is primarily for decorative purpose.
Trade name and emblem are the examples.
Embossing is similar to Ribs.
But embossing ensures added rigidity than the ribs.

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Sheet Metal Cupping
Concept
In "drawing or "deep drawing", flat sheets are formed
into cylindrical or box shaped parts by a punch that presses
the blank into a die cavity.

Metal drawing refers to those operations which exert tensile and
associated compressive stresses over a large area of the blank or
forming part.
Unlike bending in which metal is plastically worked in a relatively
small area, drawing impose plastic deformation over large areas.
Not only are large areas of the forming work piece being deformed,
but the stress states are different in different regions of the part and
complicated stress states arise in complex parts.

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DRAWING



In "drawing", flat sheets are formed into cylindrical or box
shaped parts by a punch that presses the blank into a die
cavity.
Shape can be any regular or non regular shapes.
Drawing operation mainly consists of Metal flow rather
than Metal movement.
Unlike bending operations in which metal is plastically
worked in a relatively small area, drawing operations impose
plastic deformation over large areas.


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DRAWING OPERATIONS
DRAWING
Cupping
Box Drawing
Shallow Panel Drawing
Deep Panel Drawing
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CUPPING











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CUPPING

Since it involves only the drawing process it is called as
true drawing.
Cupping is the drawing of parts having circular or cylindrical
shape.
Cup may be single cylinder or several cylinders with
different diameters with or with out tapered sides.
But in top view all contours should appear in circles.
Since circular stress through out the cup during drawing are
uniform.
Compressive stress in flange area is constant at any radial
point.
Tensile stresses in wall are equal at any point taken near the
bottom.
Tendency for wrinkling and breakage is equally severe at all
the points around the flange.
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REDRAWING
















In this process cup sits on top of die steel.
Punch steel and blank holder must sit inside the cup.

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REVERSE REDRAWING











The cup is placed on the die steel upside down.
The outside diameter of the die steel acts as locator, which
holds the cup centrally with punch steel.
When reverse redrawing, the cup is turned inside out as it is
reduced in diameter.

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BOX DRAWING



Drawing of Square or rectangle shapes are called box
drawing.
In this excess of metal, compressive stresses and wrinkling
occur only at the corners during box drawing.
Corners require more blank holding force to resist wrinkling.
Box drawing is basically forming at the straight sections and
drawing at the corners.

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PANEL DRAWING
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PANEL DRAWING



Drawing of irregular shaped part i.e not a standard
geometric shape is called panel drawing.
Parts resulted from this operations are called panels.
Contours of the parts change irregularly, causing wide
variations of stresses.
Wrinkling of metal and excess of metal may occur in one
section, while deficiency at another section.
Predicting stress is difficult. Wrinkling is not limited to flange
as cupping.
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SHALLOW PANEL DRAWING

Low panel height indicates shallow drawing.
This drawing incorporates a great deal of stretch-forming of
metal.
DEEP PANEL DRAWING


If panel height is great the operation is called deep
drawing.
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SESSION II



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BEND ALLOWANCE











Bend allowance is the true, flat length of material required
to go around a given radius (bend line to bend line) along the
neutral axis.
Line in the metal that is neither compressed nor stretched
with in the thickness is called as Neutral axis.


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K - FACTOR


K Factor is not a Bend allowance.
K is the Number which positions the Neutral axis.
When the blank is first being bent, the neutral axis is near
the center of the sheet thickness.
As bending progresses, the neutral axis shifts toward the
inside, or compression side, of the bend.
Normally, the neutral axis is measured as a certain distance
from the inside surface of the sheet metal at the bend area.

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Neutral Axis Location
Bend Radius
&
Neutral Axis
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Constant sheet-metal thickness, the neutral axis shifts closer to
the inside surface as the radius of bend is decreased.

Constant bend radius, the neutral axis shifts closer to the inside
surface as the sheet-metal thickness is increased.

Sheet metal thins slightly in the bend area.
The inside surface bends tightly on the die radius and is held
to closer tolerances.
Therefore, most parts are dimensioned using radii to the
inside surfaces.




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Bend Allowance & K-Factor Relations
Bend Axis Location depends on,

Material itself
Radius of Bend
Ambient Temperature
Direction of Material Grain
Method by which it is being bent

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STRESS RELIEF CUTS
Stress relief cuts are created by removing the minimum
material necessary to avoid material tear during a bend
operation

Types






Circular
Elliptical or Slotted
Rectangular
Triangular
Slit
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STRESS RELIEF CUTS
Bend Types

Bends with No overlap
Bends with Overlap


Stress Relief Cut on No Overlap Bend
Stress Relief Cut on Overlap Bend
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SPRING BACK
What is it?

Springback is usually expressed in terms of initial (in-die) and
final bend radii
Spring Back = Rinitial / Rfinal

Variables and their effects on springback
Bends with No overlap.
Harder sheet metals have greater degrees of springback due
to their high yield strengths .
A sharper or smaller bend radius reduces springback by
creating a larger plastic zone.
But higher stresses in the outside surface can lead to
fracture.
Thicker sheets have less springback because more plastic
deformation occurs for the same die radius

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SPRINGBACK COMPENSATION




Over Bending






Bottoming





Stretch Bending





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GRAIN DIRECTION

Cold rolling of sheets produces anisotropy because of
alignment of impurities, inclusions, and voids and this is called
Mechanical Fibering
Directional line in the sheet along the rolling direction.
When metal is bent parallel to this direction, cracking
sometimes occurs due to the material structure.
To avoid this, bend lines should be perpendicular to the
rolling direction.
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END CONDITION

Defines How panels will interact along adjacent non bend
edges.
Material to be eliminated at from one panel by overlapping
area.

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MIN FLANGE WIDTH

Minimum Flange width should be at least 4 times the metal
thickness plus Bend radius.

Violation of this Rule will cause the following,
Distortion in the part
Damage to the tooling or Operator due to slippage

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HOLES / SLOTS

Holes and Slots should be located at least 3 times the metal
thickness plus Bend radius.
If it is must to have closer, then holes/slots should be
extended beyond the bend line.
Violation of this rule can cause distortion in the Hole/Slot.

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Thank You !!!