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Press Working Operations - Sheet Metal
Press Working Operations - Sheet Metal
LANCING Embossing/
Form Beads
JOGGLE
THEORY OF CUTTING
Radius of bend T
Minimum height of bend 3T
Height of flange after
0 +/- 1.0
90 flanging = 9.0
( except at corners and feature lines)
ANGULAR
BEADS
V-BEADS
BEAKS
THEORY OF DRAWING
• Drawing is a process in which the punch causes a flat , precut metal
blank in to the die cavity to assume the shape of seamless hollow
vessel without excessive wrinkling, thinning, or fracturing.
• METAL FLOW IN DRAWING PROCESS
when the punch of draw die forces a portion of metal blank through
the bore of draw ring, different forces such as radial tension,
circumfrential compression and bending & frictional forces come in
to action as shown in the fig.These forces cause a complicated
plastic flow of the material in the blank. The volume and the
thickness of the component remain constant and the final shape of
the cup will be similar to contour of the punch.
The progressive stages of cupping are schematically shown in fig.
After a small stroke of the punch, cupping stage A, the metal
elements 2, 3, 4, & 5 of the blank move radially toward the center
of the blank. The flow of these elements go on till the final stage C
of the cup is reached. Thus by the end of the draw of the cup area 1
is unchanged in shape and size in the bottom of the cup. The areas
2,3 & 4 change from the shape of angular segments to longer
parallel-sided shapes and area 5 also changed in it’s size and shape.
Due to this metal flow phenomena in Drawing operation, Blank
holding pressure is to be applied on the blank in such a way that the
metal flow will be a controlled one so as to avoid wrinkling, tearing,
thinning etc.
DESIGN CONSIDERATIONS FOR CYLINDRICAL CUP DRAWING
Empirical Rule to decide required If =h/d No. of Draws
no. of Draws for Cylindrical cup Up to 0.75 --------- 1
(Where h = inside height of shell 0.75 -- 1.5 --------- 2
d = Mean dia. Of shell) 1.5 -- 3.0 --------- 3
3.0 -- 4.5 --------- 4
Drawing Force for Cylindrical Cup Fd = d t (Su + Sy)/2 Kg.
(Fd)
Where d = Punch diameter (mm.)
2
Su = Ultimate Tensile strength (Kg/mm )
2
Sy = Yield strength (Kg/mm )
T = Thickness of sheet. (mm.)
Blank Holder Force(Fb) Fb = 1/3 of Drawing force(Approx.)