TOPICS

• BENDING

• DRAWING

• FORMING

• FINE BLANKING
BENDING OPERATION
 PRINCIPLE OF BENDING
In bending operation, the material in the form of flat
sheet is uniformly strained around a linear axis which
lies in the neutral plane & perpendicular to the
lengthwise direction of the sheet.

Bending of sheet metal has the distinct

characteristic of stretching the metal at localized areas
only. The localized stress or pressure occurs only at
bend radius . the remaining flat metal is not stressed
during bending. The metal on the outside of the bend
radius has been stretched indicating tensile stress has
been applied. The metal on the inside of the bend radius
has been squeezed or placed under a compressive
stress.
 STRESSES IN BENDING
TENSILE STRESS
(X).
NEUTRAL AXIS For a good bend design the
tensile stress at point "X" is
0 below the ultimate tensile
NEUTRAL AXIS strength
T COMPRESSIVE
C STRESS
At point "O" both
Shaded area
stresses are zero i.e. on
under stress.
neutral axis stress is
C- Compression No stress in zero.
T- Tension this area.
STRESS INDUCED
DURING BENDING

STRESSES IN BENDING
 ELEMENTS OF BEND
Bend Axis &
Bend Radius

Outer Surface
Bend
Allowance Bend Angle Inner Surface
Bend Area
Bend Lines

ELEMENTS OF BEND
 ELEMENTS OF BEND
 NEUTRAL AXIS:- The line of zero stress is called
neutral axis.
 BEND ALLOWANCE:- Length of neutral axis in affected
zone is called bend allowance.
 BEND ANGLE:- It is the angle between two
perpendicular lines drawn from flange to center of radius.
 NEUTRAL PLANE:- The plane in the material in
between the outer & inner layers experiences no stress.
This is called neutral plane.
 GRAIN DIRECTION

Direction of grains Direction of grains

Bending Across Grain Bending Along Grain
Direction Direction

GRAIN DIRECTION
Grain Direction
 SPRING BACK
 SPRING BACK :- In metal working process the total
deformation imparted to a work piece will be sum of
elastic deformation & plastic deformation. The elastic
deformation is recoverable where as plastic deformation
is permanent. So that at the end of metal working
operation when the pressure on the metal is released
there is an elastic recovery by the material & the total
deformation will get reduced to a little .This phenomenon
is called spring back.
 SPRING BACK FORCES
Metal zone plastically
deformed by tension.

SPRING BACK

SPRUNG BACK FORCES

Metal zone plastically ELASTIC METAL BAND

deformed by
compression.
NEUTRAL AXIS IN WIPING SPRING BACK
U BENDING

SPRING BACK FORCES

 VARIABLES & THEIR EFFECT
ON SPRING BACK.
 Harder sheet metal would have more degrees of spring
back due to a higher elastic limit & resulting a larger
elastic band at the bend.
 A sharper or smaller bend radius would reduce spring
back by creating a larger plastic zone & could cause
tearing due to higher stresses in the outside surface.
 As metal is bend through more degrees of bend the
plastic zone is enlarged & spring back is reduced for
each degree of bend.
 Thicker sheet metal have less spring back since more
plastic deformation occurs.
SPRING BACK CALCULATION
SPRING BACK CALCULATION
 METHODS OF OVERCOMING
SPRINGBACK
Following methods are used to reduce spring back
effect.

 OVER BENDING.

 CORNER SETTING OR BOTTOMING.

 STRECH BENDING.
 OVER BENDING

Bending in a v die, Part spring back

punch & die both in all cases
shown to 90°.
undersize at 85 °.

OVER BENDING
 CORNER SETTING

Here material is
permanently
deformed
U-Bending V- Bending
CORNER SETTING
BOTTOMING FORCE

PUNCH

0.5 B 0.5 B
B

PAD DIE

U BENDING V BENDING
Where,
Minimum Bottoming force (Fb). YS = Yield strength in N\mm²
B = Plan projected width of bead in mm.
Fb = (YS) * W * B W= Width of sheet metal at bendin mm.

BOTTOMING FORCE
STRETCH BENDING

CLAMP Clamps grips & strech the

metal beyond its elastic limits
as they pull sheet metal over
the punch contour.

PUNCH

STRETCH BENDING.
COMPENSATING SPRING BACK
PUNCH

DIE

Component After
PAD
Bending
Punch Concave
Pad Convex

COMPENSATING SPRING BACK

BLANK LENGTH CALCULATION
Neutral Where,
axis L1 R B= Bend allowance.
T
R=Bend radius.
B T=Sheet thickness.
L2
L1 & L2=Length.
Blank before Blank after
bending bending
Total Blank Length= L1+B+L2

BLANK LENGTH CALCULATION

BEND ALLOWANCE
BEND ALLOWANCE (B) = X ( r + c)
180
Where,
= Bend angle.
r = Bend radius.
t = sheet thickness.
C= Constant(Die clearance).
( The value of c depend upon r & t values).
When,
r > 4t then c = 0.5 t
r = 2t to 4t then c = 0.4 t
r < 2t then c = 0.33t
 METHODS OF BENDING
Methods of bending are as follows.

 ”V” BENDING.

 WIPING.

 “U” BENDING.
 V BENDING
PUNCH

BLANK

DIE

ROCKING PULLING

V - BENDING

BOTTOMING
WIPE BENDING
 U BENDING
PUNCH
BLANK

DIE

GRIPPING SWUNG

WIPING BOTTOMING

U BENDING
STRESSING OF BEAM
F

End view of Beam

Cantilever Beam

S=MC I = b h³ Where,
I 12 S = Stress in N/mm²
C = h/2 M= FxL
M = Bending movement Nmm
I = Moment of inertia.
S = F L x (h\2) C = Centroid distance.
bh³\12
F = Force in "N".
F = Sbh³ x 2 L = Span in mm.
12 Lh
b = Base of beam in mm.
F = (.167) Sbh² h = Height of beam in mm.
L
 FLANGE LENGTH
T
BLANK

a= W-T
1.41
a
DIE

W Where,
W= die opening.
T= Sheet thickness.
a= Minimum flange length.
FLANGE LENGTH
 FORCE FOR V-BEND
Force required for V- Bending

Fb = K L T ² F t
W
Where,
L = Transverse Length of the bend
i.e width of the blank in "mm".
t = Thinkness of the blank in "mm".
Ft = Tensile strength of the blank in "N/mm²".
W = Width of the V at top i.e die opening.
K = Constant ( 1.2 to 1.33)
FORCE FOR WIPING
PUNCH
PAD
x F
r1 t
W
r2 C End view of sheet metal blank
DIE L
Where,
F=Force for wiping in" N".
Bending occur at"X". t= Sheet metal thickness mm.
w= Sheet metal width at bend mm.
L= Span mm.
F= .333* S W T² r1=Punch radius mm.
r2=Die radius mm.
L C= Die clearence mm.
S= Ultimate tensile strength N\mm²

FORCE FOR WIPING

 FORCE FOR U-BEND

F= .667* S W T²
Where,
L F=Force for bending in" N".
t= Sheet metal thickness mm.
w= Sheet metal width at bend mm.
L= Span mm.
S= Ultimate tensile strength N\mm²

F= .333* S W T²
2xL
 PAD FORCE
PAD P PUNCH
F

Where,
X P =Pad force.
A L F = Bending force.
DIE L= Span.
A= Span (A=2L).

Considering dimension A to be equal to twice the span L.

PAD FORCE * A = BENDING FORCE *L

P * 2L = F*L

P = 0.5 F

PAD FORCE
COMPONENTS OF BENDING
BENDING TOOL
TOP HALF
BOTTOM HALF
ASSEMBLY
EX1-A COMPONENT OF COPPER SHEET 0.25 HARD WITH IS TO BE
BEND TO AN ANGLE OF 90 CALCULATE THE ANGLE OF THE RADIUS
TO BE PROVIDED ON THE DIE FOR THE SHEET THICKNESS 0.3 mm k =
0.93 ,R2 = 3MM.

K= (R1 + S/2 )/ (R2 + S/2)

0.93 = (R1 + 0.3/2) / (3+0.3/2)
0.93 X (3+(0.3/2) = R1 + (0.3/2)
R1 = 0.93 X (3 +0.3/2) /(0.3/2)
R1 = 2.7795 mm
RADIUS OF PUNCH = 2.7795
DIE RADIUS = 2.7795 + S
=2.7795 + 0.3
= 2.0795 mm
DIE ANGLE = 180 – α1
K = α2 /α1
0.93 = 90/α1
α1 =90/0.93
= 96.77
DIE ANGLE = 180 – α1
= 23.22
CALC. THE BENDING ANGLE TO BE PROVIDED & RARIUS. COMP. IS MADE UP
ON Al zink allow 2 mm SHEET THICKNESS TO BE BEND TO 90 WITH RADIUS
OF 10 mm k= 0.9

K= (R1 + S/2 )/ (R2 + S/2)

0.9 = (R1 + 2/2) / (10+2/2)
0.9 X (10+(2/2) = R1 + (2/2)
R1 = 0.9 X (10 +2/2) /(2/2)
R1 = 8.9 mm
RADIUS OF PUNCH = 2.7795
DIE RADIUS =8.9+ S
=8.9 + 2
= 10.9 mm
DIE ANGLE = 180 – α1
K = α2 /α1
0.9 = 90/α1
α1 =90/0.9
= 100
DIE ANGLE = 180 – α1
= 80
DRAWING
 DRAWING
Drawing is a process of axial elongation
through application of axial force. In sheet metal
drawing a flat sheet is deformed into a deep cup.
 BASIC DRAW TERMINOLOGY
Certain basic terms are particularly related to the
draw operation . That are as follows.
 Drawing – A process by which seamless
vessels are formed from flat stock material.
 Redrawing– A drawing operation in which
previously drawn vessel are drawn deeper &
reduced in their crosswise dimension.
 Shallow draw– A drawn piece part which
require only one drawing operation.
DRAWING PROCESS

PUNCH

BLANK
HOLDER

BLANK
DIE

BOTTOM
PLATE

The blank of diameter D The pressure pad moves

is loaded on the drawing down & clamps the
tool.(1). workpiece.(2).

STEPS IN DRAWING
DRAWING PROCESS

PUNCH

PUNCH
HOLDER

BLANK
DIE

BOTTOM
PLATE

The blank of diameter D The pressure pad moves

is loaded on the drawing down & clamps the
tool.(1). workpiece.(2).

STEPS IN DRAWING

The draw punch (dia d) starts to
draw the blank through the draw
die. The blank flows over the draw
radius.The blank of diameter D is
reduced to cup diameter d.(3).
The punch has reached its lowest portion
completing the draw operation & at this
junction punch assembly starts to retract
to its original position.(4).

STEPS IN DRAWING
 METAL FLOW

Each section must

compress more than
the previous section

Drawing blank is divided

into 4 concentric element Punch moves down and touch
and each element into
the blank. ( no metal
segment
movement)

Metal in this area will

strenthen upon further
penetration.

METAL FLOW DURING

The draw punch starts to DRAWING
draw the blank through
draw die.
 FORCES ACTING ON THE
COMPONENT DURING DRAWING
Blank holding
force

Compression Radial
Circumferential Tension

2) Circumferential 2) Radial tension on the

compression on the flange. flange.

Tension at side
Bending at edges.
walls.

3)Bending at edges.

FORCES ACTING ON THE

COMPONENT WHILE 4)Tension the side walls.
DRAWING
 DIE CLEARENCE
Die clearance:-
The space for drawing is kept
intentionally bigger by 7 to 15% the work sheet
thickness. This additional gap over & above sheet
thickness is called die clearance.
In addition to providing space for wall
thickening, the clearance reduces friction between
the die sides & work piece.
 CLEARANCE FOR DRAWING
DIES
Sr.no. Blank First Redraw Sizing
thickness draw draw
1 Up to 1.07 t - 1.08 t - 1.04 t -
0.4mm 1.09 t 1.11t 1.05t
2 0.45mm - 1.08 t - 1.09 t - 1.05 t -
1.25mm 1.1t 1.12 t 1.06 t
3 1.30mm - 1.1 t - 1.12 t - 1.07 t -
3.15 mm 1.12t 1.14t 1.09t
4 Above 1.12 t – 1.15 t – 1.08 t –
3.20mm 1.14 t 1.20 t 1.11 t
 CLEARANCE FOR DRAWING
DIES
Above clearance are applicable for
drawing mild steel having shear strength 390 N\
mm². For other material having different shear
strength the clearance would be,

clearance = 390 x clearance for m.s.

work piece shear strength.
PUNCH & DIE RADIUS

Punch radius
(Rp).
Die radius
(Rd).

PUNCH & DIE RADIUS

 DIE RADIUS
The first drawing die radius (R),

R (die- first) = √ 0.8 (Do - d) * to

Where,
Do = Blank diameter.
d = Inner diameter of shell.
to = Thickness of blank.
 Die radius
The redrawing die radius (R),

R (redraw) = (d1 – d2) * to

2
Where,
d1 = Shell diameter before redrawing.
d2 = Shell diameter after redrawing.
to = thickness of blank.
 PUNCH RADIUS
Drawing punch radius (Rp) values differ with the
diameter of shell “d” as follows,

 For “d” = 6mm to 100mm Rp = 3t to 4t.

 For “d” = 100mm to 200mm Rp = 4t to 5t.
 For “d” = above 200mm Rp = 5t to 7t.
Where,
t = Sheet thickness in mm.
BLANK CALCULATION
Cup Diameter "d".

Sheet
Thickness"t". Cup Height
"h".

Radius"r".

BLANK SIZE CALCULATION

 BLANK CALCULATION
Area of cup = bottom area + cylinder area
= π/4 (d²) + π * d* h
= π/4 (d² + 4dh)
If “D” is the diameter of blank,
Blank area = π/4 (D²)
Equating cup area with the blank area,
π\4 (D²) = π/4 (d² + 4dh)
D =√ d² + 4dh
 BLANK DIAMETER
D =√ d² + 4dh When d\r > 20.

D =√ d² + 4dh – 0.5r When d\r = 15 to 20 .

D =√ d² + 4dh – r When d\r = 10 to 15

D =√ (d – 2r)² + 4d(h – r) + 2π r( d – 0.7 r)

When d\r < 10.
BLANK CALCULATION
BLANK CALCULATION
BLANK CALCULATION
BLANK CALCULATION
AREA CALCULATION

R
D

H AREA = R H R ²
AREA =  R D
R

R ²
AREA =  R D

R AREA = 2 R ² R

R
AREA =  R D ²
R D
H AREA = R H

AREA = 2 R ² ²
+  R D
d R

s= h²+c² D

H AREA = S ( d1 + d2)

s D

2 R AREA = 2 R ² + ²R D

d
 HEIGHT OF SHELL
Height of shell (h),
h = D² - d²
4d
Where,
h = height of shell.
d = Mean diameter of shell.
D = Blank diameter.
 HEIGHT OF SHELL
The height of shell subjected to n – redrawing
operation is (hn),
hn = t (D² - dn²)
4dn * tn
Where,
dn = Diameter of the shell after n redrawing.
tn = Thickness of the wall.
t = Original thickness.
 NUMBER OF DRAWS
Number of draw for a particular component will
depend upon “ h/d” ratio.
Where,
h = Inside height of shell.
d = Mean diameter of shell.
h/d ratio No. of draws
< 0.75 1
0.75 – 1.5 2
1.5 – 3 3
3.0 – 4.7 4
 REDUCTION RATIO
Reduction ratio for first draw,
d1 = B1 * D
100 - .635D
For n - redrawing dies,
dn = B2 * d (n-1)
100 - .635 d (n-1)
Where,
D = Blank diameter.
d1 = mean diameter of first shell.
d(n-1) = mean diameter of ( n-1) shell.
B1 & B2 = Factors depends upon material
thickness.
 Stock First Any redrawing
thickness(mm). operation die die (B2)
(B1) value. values.
0.3 - 0.45 61 74
0.5 53 73
0.55 – 0.6 56 72
0.7 54 71
0.8 50 70 - 71
1.5 – 2.7 47 70
3 – 6.35 51 65
 REDUCTION RATIO
Reduction ratio = (D – d) * 100
d
% reduction values

For 1st operation. 40 %

For 2nd operation. 25 %
For 3rd operation. 18 – 20 %
For 4th operation. 10 – 15 %
 BLANK HOLDER
To decide whether to go for blank holder is
depend upon “t\d” ratio.
 When (t\d) *100 < 0.5 :- Wrinkling is severe
blank holder is must.
 When (t\d) *100 between 0.5 – 1.5 :- Wrinkling
is moderate low blank holder force are permitted.
 When (t\d) *100 between 1.5 – 2.5 :- Wrinkling
is very slight single action dies are used.
 When (t\d) *100 > 2.5 :- No wrinkling is
expected so that blank holder is not necessary.
 BLANK HOLDER
To decide whether to go for blank holder is
depend upon “(D –d)\ t” ratio.
D – d < 18 No blank holder needed.
t
D – d > 18 Blank holder needed.
t
Blank holding force (Fb),
Fb = (0.2 – 0.4) Fd
Where,
Fd = drawing force.
 FORCE FOR DRAWING
Drawing force (Fd),
Fd = π *d * t Su + Sy “N”
2
Where,
d = Punch diameter in mm.
Sy = Yield strength of material N\mm².
Su = Ultimate tensile strength N\mm².
t = Thickness of sheet in mm.
 FORCE FOR DRAWING
Total force for drawing (Ft),
Ft = Fd + Fb
Where,
Fd = Drawing force in N\mm².
Fb = Blank holding force in N\mm².
Energy for drawing (Ed),
Ed = 0.9 * Fd * h
Where,
h = Height of cup in mm.
 AIR ESCAPE HOLE

Blank Holder

Air escape hole 6 MM for drawpiece 25-50 mm

for punch Punch in diameter.
8 MM for drawpiece 50-100 mm
in diameter.
Die
10 MM for drawpiece 100-200
Air escape mm in diameter.
Pad hole for die

AIR ESCAPE HOLE

 DRAW BEADS

Where
A = Width of bead in mm.
1) Internal Bead. 2) External Bead.
a = Maximum possible internal
bead depth mm. ( a= radius).
T = Sheet thickness mm.
S = Tensile strength N\mm^2.
R P= Forming pressure N\mm^2.
a R= Bottom radius mm.
A = 4 to 6 R = 2( TS) (circular bead)
a P
R = ( TS) (elongated bead)
P

DRAW BEADS
 TRIMMING
Cup or flange edges often get damaged &
distorted in drawing. As soon as the outer edge
reaches the draw radius it looses contact with
the blank holder & is no more under it’s
pressure. Thus the last drawn portion is likely to
be wrinkled. This portion is trimmed off to finish
the drawn work piece size.
This trimming operation is performed with
the help of scrap cutters, trimming dies,
trimming machines.
 TRIMMING ALLOWANCE
Cup Trimming allowance\side (mm).
thickness Cup Hardness Rockwell “B”
(mm).
50 – 65 75 – 90 90 – 106

1.2 0.63 0.75 1.06

1.6 0.75 1.06 1.25
2.0 0.90 1.25 1.5- 1.8
2.36 1.06 1.50 1.8 – 2.24
2.80 1.25 1.80 2.24 – 3.30
 DRAWING RECTANGULAR
CUPS
Drawing is also used for making
rectangular boxes. Component made by
rectangular drawing are,
 Engine oil pans.
 Gasoline tanks.
 Sinks.
BLANK DEVLOPMENT
L
H

R T r
W

Where
L= Length of the component.
W= Width of the component.
T= Sheet thickness.
H= Height of component.
R= Corner radius joining vertical sides of the box.
r= Corner radius joining horizental bottom to vertical sides
of the box.

DRAWN COMPONENT
BLANK CALCULATION

L
H

R T r
W

Where
L= Length of the component.
W= Width of the component.
T= Sh eet thickness.
H= Height of component.
R= Corner radius joining vertical sides of the box.
r= Corner radius joining horizental bottom to vertical sides
of the box .

DRAWN COMPONENT

3.1 4*r + H
Rc Rc
2
Where,
Rc= Corner radi us.
3.1 4*r + H W - 2R 3.14*r + H
2 2
3. 14*r + H Rc
Rc
2

L - 2R

DEV LOPE D LENGTH

DEVLOPED BLANK
 CORNER RADIUS
Corner radius (Rc),

Rc = R + 2 R h - 1.141 R r
Where,
R = Corner radius joining vertical sides
of the box.
r = Corner radius joining horizontal
bottom to vertical sides of the box.
h = height of the box.
 REDUCTION RATIO
Reduction ratio = (R – r) * 100
R
% reduction values

For 1st operation. 45 %

For 2nd operation. 25 %
For 3rd operation. 18 – 20 %
For 4th operation. 10 – 15 %
REDUCTION RATIO

Corner radius r.

Effective blank
radius R.

Rectangular or square
edge prior to drawing

TOP VIEW OF BOX CORNER

NUMBER OF DRAWS

No. of draws based on Ratio of

height to corner radius

h/r No. of Draws

Up To 6 1

Up To 12 2

Up To 17 3

Up To 22 4
 FORCE

Force required for Rectangular Drawing

Frd = Ft x t { 2 R C1 + L C2}
Where,
T = Thickness Ft = UTS R = Corner radius
C1 = Constant Depend on H/R.
0.5 - very shallow shell
Up to 2 - shallow depth 5 to 6 times corner radius " r "
L= Total length of straight sides of rect. shell.
C2 = Constant (0.25).
 IRONING
Ironing is used for thinning the walls of
drawn cups. The wall thickness can be reduced by
30 – 35% of the unironed thickness in a single
operation. The bottom thickness dose not change
in ironing.
Ironing dies are same as drawing dies,
the only difference being the tolerance between
the drawing punch & the die which in ironing dies
is smaller. This change results in drawn becoming
forcibly thinner & the shell wall surface uniform &
smooth.
STAGES IN IRONING

Third draw
Second draw
First draw
Blank

IRONING
 IRONING RATIO

IRONING RATIO ( Ei )=
Ei = to
t
Where,
to = Thickness of cup before ironing.
t = Thickness of cup after ironing.
 REDUCTION RATIO
Reduction ratio (Ri),
Ri = to – t *100
t

Where,
to = Thickness of cup before ironing.
t = Thickness of cup after ironing.
RELATION BETWEEN Ei & Ri

Ei = 1
1 – Ri

Where,
Ei = Ironing ratio.
Ri = Reduction ratio.
 FORCE CALCULATION
Force required for ironing (Fi) =
Fi = [ 1.2 * π* dm *ti * Sm ] * log t
ti
Where,
dm = Mean diameter of shell after ironing.
t = Thickness of shell wall before ironing.
to = Thickness of shell wall after ironing.
Sm = Mean stress before & after ironing.
 FORCE CALCULATION
Force required for ironing (Fi)=

Fi = 3.2 * Fd * t – ti
t
Where,
Fd = Force required for drawing cup
before ironing.
 ENERGY FOR IRONING
Energy required for ironing (Ei),

Ei = 0.7* Fi * h

Where,
Fi = Ironing force.
h = height of ironed wall.
 INTER STAGE LENGTH
Cup length after cupping draw (l1),
l1 = D² - d²
4d
Where,
D = diameter of the blank.
d = diameter of the drawn cup.

Length of shell after passing 1st ironing die (l2),

l2 = ( Ei ) * l1 (d + to)
(d + ti)
Where,
Ei = ironing ratio.
d = diameter of cup.
to = thickness of cup before ironing.
t1 = thickness of cup after ironing.
 INTER STAGE LENGTH

Length of shell after passing through nth

ironing die (ln),
ln = Ei (n-1) * l (n-1) { d + t(n-2)}
{d + t(n-1)}
DRAWING COMPONENT
DRAWING TOOL
TOP HALF
BOTTOM HALF
DRAWING TOOL
FORMING
 EMBOSSING
Embossing is a shallow forming
operation. The component material is
stretched over a die & made to confirm
to the die surface by a punch.
The finished product will have a
depressed detail on one side & a raised
detail on the other.
 PURPOSE OF EMBOSSING
Embossing is done to,
 Stiffen & strengthen a sheet metal part.

 Impart a raised or depressed design on

the surface of the part.
 For decorative purpose.
EMBOSSING THEORY
Work hardning occurs
B only in shaded area.

A Blank after embossing

Blank before embossing

Length A is being streched to length b
to create emboss depression.

EMBOSSING PRINCIPLE
 EMBOSSING FORCE
Force required for embossing,
Fe = S*t*L

Where,
Fe = Embossing force in “N”.
S = Ultimate tensile strength in N\ mm².
T = Sheet metal thickness in mm.
L = Emboss length in mm.
 BOTTOMING FORCE
Force required for bottoming is,
Fb = Sy * A

Where,
Fb = bottoming force in “N’.
Sy = Yield strength of material in N\mm².
A = Plan projected area of bottoming zone

in mm².
EMBOSSING COMPONENT
HOLE FLANGING
 HOLE FLANGING
HOLE FLANGING :-
Hole flanging or collar drawing is a
process in which a collar is formed on the
sheet metal component
PURPOSE OF HOLE FLANGING
Many sheet metal assembly component
require threaded holes so that they can be
fastened with other element of assembly.
If sheet thickness is less it is not possible
to provide sufficient number of threads. So
that hole flanging is used to provide more
number of threads.
METHODS OF HOLE FLANGING
Their are two methods of hole flanging,
 In first method both operation i.e. piercing
& flanging are performed independently.
 In second method both operation are
performed simultaneously.
HOLE FLANGING PROCESS

Blank before Blank after

hole flanging. hole flanging.
Both operations ( Metal become thinner due to
are performed on streching. Thinnest at top of
different station. flange.)

STEPS IN HOLE FLANGING

HOLE FLANGING PROCESS

Blank before Blank after

hole flanging. hole flanging.
Both operations ( Metal become thinner due to
are performed on streching. Thinnest at top of
one station. flange.)

STEPS IN HOLE FLANGING

 DESIGN PARAMETERS

Where,
d
d = diameter of prepierced hole in
t mm.
R H
R = Outside radius of flanged hole
A
in mm.
B t = sheet thickness in mm.
H =height of flanged hole in mm.
B= Outside diameter of flanged
DESIGN PARAMETERS hole in mm.
FOR HOLE FLANGING A = Inside diameter of flanged hole
in mm.
 DESIGN PARAMETERS
B = A + 5t For t < 1.2 mm. (outside diameter)
4
B=A+t For t > 1.2mm.

H=t For t < 0.9 mm. (height of flange)

H = 4t For t = 0.9 to 1.25 mm.
5
H = 3t For t > 1.25mm.
5
 DESIGN PARAMETERS

R= t For t < 1.2 mm. (radius of flange)

4
R= t For > 1.2 mm.
3
PRE PIERCED HOLE SIZE

Pre pierced hole size (d).

d² = tB² + 4tA² + 4HA² - 4HB²
9t

Where,
d = diameter of prepierced hole in mm.
R = Outside radius of flanged hole in mm.
t = sheet thickness in mm.
H =height of flanged hole in mm.
B= Outside diameter of flanged hole in mm.
A = Inside diameter of flanged hole in mm.
 FORCE CALCULATION
Force required for hole flanging after pre
pierced the hole (Ft).
Ft = (1.5 to 2 ) π * d *t * Ssh.

Where,
d = Diameter of pre pierced hole in mm.
t = sheet thickness in mm.
Ssh = Shear strength of material in N\mm².
 FORCE CALCULATION
Force required for direct piercing &
flanging(Ft).
Ft = ( 2 to 2.5 ) π * d *t * Ssh.
Where,
d = Diameter of pre pierced hole in mm.
t = sheet thickness in mm.
Ssh = Shear strength of material in N\mm².
PUNCH DESIGN
COMPONENT OF HOLE
FLANGING
HOLE FLANGING DIE
TOP HALF
BOTTOM HALF
ASSEMBLY
COINING
 COINING

Coining is a process in which a flat

blank is cold forged to form some
depression & raise some protrusion to
effect desire pattern & impression.
 APPLICATION
Coining is widely used in the
manufacture of,
 MEDALS.

 COINS.

 BADGES.
 COINING DIE

PUNCH
COMPONENT

DIE

COINING TOOL
 FORCE CALCULATION
Force required for coining (Fc),

Fc = A * Pc

Where,
A =Total area of deformed surface mm².
Pc = surface pressure in Kg\mm².
 SURFACE PRESSURE
MATERIAL LETTERS & COINING ON
PATTERNS TWO SIDES

99% OF ALUMINIUM 5–8 8-12

ALUMINIUM ALLOY 15 35

BRASS 63% CU 20-30 150-180

SOFT COPPER 20-30 80-100

Cu – hard 30-50 100-150

 SURFACE PRESSURE
MATERIAL LETTERS & COINING ON
PATTERNS TWO SIDES
NICKEL 30-60 160-180
GERMAN SILVER 30-40 120-150
STEEL 30-40 120-150
STAINLESS 60-80 250-320
STEEL
SILVER - 150-180

GOLD - 120-150
FINE BLANKING
 FINE BLANKING
 FINE BLANKING :-
Fine blanking is a special form of
blanking which not only produces
finished edge on cut part but also work
to a close tolerance.
This process uses very tight
clearance between punch & die which
amount to some 0.5% of the material
thickness.
FINE BLANKING PROCESS
PUNCH
SPRING LOADED
PRESSURE PAD
"V" RING
BLANK
DIE PAD
DIE
Punch descend downward Locating & pressing with v ring.

Punch cuts the material. Component is ejected.

FINE BLANKING OPERATION.

 ADVANTAGES

 High precision of work.

 Further finishing is not necessary for
fine blanking component.
 Flatness of component will be better
than conventional
 In fine blanking burr is less because
reduced cutting clearance.
 DISADVANTAGE

 A tapered edge of blanked part, which

is due to friction between the blank &
die opening.

 V marks on the material which is

thrown as scrap due to which scrap
increases.
 APPLICATION

Fine blanking can be used for sheet

thickness ranges from 0.7 to 14 mm .

Sheet thickness below 0.7 are difficult to

fine blank because of pressure of v ring.
V- RING DESIGN PARAMETERS

PUNCH
ANGLE
PAD

V RING h Where,
a a = Distance between punch
PUNCH
edge & v center.
a = 0.2 to 0.4 t h = Height of v.
ANGLE = Two combinations
h= 0.2 to 0.4 t 45-45 & 45-30
t = sheet thickness.

V RING DESIGN PARAMETERS

FORCES IN FINE
BLANKING
Fb

Fr Fr

Where,
Fb = Blanking force.
Fr = Force of "v" ring.
Fc = Counter force.

Fc
FORCES IN FINE BLANKING
FORCES IN FINE
BLANKING
TOTAL FORCE = Fb +Fr + FC

1) Counter force (Fc) = l x t x f

Where,
l = Cut length perimeter in mm.
t = Sheet thickness in mm.
f = Specific counter pressure ( 20 to 70 )N\mm²

2) Blanking force (Fb) = l x t x Fsh

Where,
l = Cut length perimeter in mm.
t = Sheet thickness in mm.
Fsh = Shear strength of material N\mm².

3) Force of v ring (Fr) = (0.4 to 0.6) Fb.

Where,
Fb = Blanking force N\mm².
Thank you .