Department of Mechanical Engineering,

Purwanchal campus, Institute of Engineering,

Tribhuvan University

MANUFACTURING AND PRODUCTION PROCESSES

by

Er. Anu Shrestha

18Th August 2014
Source:Dr. Shree Raj Shakya
May 2, 2013
Sheet Metal Forming Process

• Sheet – 0.4 mm to 6 mm; Plate – above 6 mm

• wide range of consumer and industrial products => beverage cans,
cookware, file cabinets, metal desks, appliances, car bodies, trailers,
and aircraft fuselages
• 5000 B. C. => household utensils and jewelry => hammering and
stamping gold, silver, and copper
• Light weight, versatile shape
• Usually cold working
Outline of Sheet-Metal Forming Processes
Outline of Sheet-Metal
Forming Processes
 Shearing (using Punch & Die)

Figure: (a) Schematic illustration of shearing With a punch and die, indicating some of the
process variables. Characteristic features of (b) a punched hole and (c) the slug. (Note that
the scales of (b) and (c) are different.)
Shearing of sheet metal between two
cutting edges
 Shearing Clearance

Figure: (a) Effect of the clearance, c, between punch and die on the
deformation zone in shearing. As the clearance increases, the material
tends to be pulled into the die rather than be sheared.
In practice, clearances usually range between 2% and 10% of the
thickness of the sheet.
(b) Microhardness (HV) contours for a 6.4-mm (0.25-in) thick AISI 1020
hot-rolled steel in the sheared region. Source: H. P. Weaver and K. J.
Weinmann.
 Characteristics of shared edges of the work

• Rollover is the depression made by the punch in the work prior to

cutting
• Burnish is the smooth region below rollover resulted from the
penetration of the punch into work before fracture
• Fracture zone is relatively rough surface of the cut edge where
continued downward movement of punch caused fracture of
metal
• Burr is sharp corner on the edge caused by elongation of the metal
during final separation of two pieces
Shearing Clearance

Figure: (a) too small clearance => excessive

force
(b) Too large clearance => oversized burr
 Shearing Operation

Figure: (a) Punching (piercing) and blanking.

• if punched out part (slug) is discarded byproduct => PUNCHING
• if punched out part (blank) is final product => BLANKING
(b) Examples of various shearing operations on sheet metal.
Shearing Operation
 Shearing along straight line between two
cutting edges
Linear shearing
• power shares or squaring shares used
• upper blade of the power shares is often inclined to reduce cutting
force
 Design parameters for blanking and
punching
• • Blanking punch diameter = Db – 2c
• • Blanking die diameter = Db
• • Hole punch diameter = Dh
• • Hole die diameter = Dh + 2c

• Clearance = clearance allowance x stock

thickness
= Ac t
Design parameters for blanking and
punching
 Cutting Force in Shearing process
Cutting Force
F=StL
S = shear strength of the sheet metal, MPa
t = stock thickness, mm
L = length of the cut edge, mm – Perimeter
length of the blank
F = 0.7 TS t L
TS = ultimate tensile strength, MPa
 Other sheet Metal Cutting Operations

a) Cut off
b) Parting
 Other sheet Metal Cutting Operations

• a) Slotting
• b) Perforating
• c) Notching and semi-notching
 Shaving and Fine blanking

Shaving
 performed with very small clearance
 Obtain accurate dimension with smooth & straight cut edge
Secondary or finishing operation
• Fine Blanking
• Blank sheet metal part with close tolerances and smooth, straight edges in one
step
• Pressure pad with a V-shaped projection applied against the work adjacent to
punch
• Useful for small stock thickness
Fine blanking
Slitting
Piercing
 Bending and drawing
• Bending => straining of the sheet metal around
a straight axis
=> both compression and tensile elongation of
the metal occur in bending
 Bending
Bending Types
 V – bending
 Edge Bending
 U-Bending
Bending direction
 Spring Back
Spring Back => elastic recovery
SB = (A’ – A’b)/A’b
• A’ = included angle of the sheet metal part, degrees
• A’b = included angle of the bending tool, degrees
• Compensation
– Over bending => using smaller punch angle and radius
– Bottoming => squeezing part at the end of stroke => plastically deforming
 Bending Force
Bending Force, N
F = (K T.S. w t2) /D
• T.S. = Tensile strength of the sheet metal, MPa
• w = width of part in the direction of the bend axis,mm
• t = stock thickness, mm
• D = die opening dimensions
• K = 1.33 for V bending
= 0.33 for edge bending
Types of Bending Process
Types of Bending Process
Bending in a Press Brake
 Drawing

• Drawing process
– Shapes => Cup shaped, box shaped, complex
curved
– Tools => Die and Punch
– End Products => Cans, sinks, cooking pots,
automobile body panel
 Drawing of cup-shaped part
Mechanics of Drawing
Db = Blank diameter;
Dp = Punch diameter;
Rp = Corner radius of punch
Rd = Corner radius of die

• Clearance,
c = 1.1 t
Drawing steps
 Drawing
• Drawing force, N
• F = π Dp t (TS) {(Db/Dp) – 0.7}
• t = original blank thickness, mm
• TS = tensile strength, MPa
• Db/Dp = Starting blank diameter and punch diameter
• 0.7 = Correction factor for friction
• • Other operations
• – Redrawing
• – Reverse drawing
Redrawing
Reverse drawing
 Defects in drawing
• Defects in drawing
– Wrinkling – In the flange - In the wall
– Tearing
– Earing
– Surface scratches
Other sheet metal forming operations

Lancing for cutting and bending/forming

Roll Forming
Tube Bending
Bulging
 Forming
Stretch forming
a sheet-metal is intentionally stretched
and simultaneously bent over the die
in order to achieve desired shape change
Stretch forming
 Stretch forming
Stretch forming Force
F = Lt Yf
– F = Stretching force, N
– L = length of the sheet in the direction
perpendicular to stretching, mm
– t = instantaneous stock thickness, mm
– Yf = flow stress of the work metal
 Conventional Spinning
• a circular blank of flat or preformed sheet metal is placed
and held against a mandrel
• Blank is rotated while a rigid tool deforms and shapes the
material over the mandrel
• tool may be activated either manually or by computer-
controlled mechanisms
• suitable particularly for conical and curvilinear shapes
 Conventional Spinning
Figure
(a) Schematic illustration of the conventional spinning process

(b) Types of parts conventionally spun. All parts are axisymmetric.

 Tube spinning

Figure: Tube spinning => (a) External; (b) Internal; and ( c) Profiling
 High Energy Rate Forming
(Explosive Forming)
1. Setup
2. Explosive is detonated
3. Shock wave forms part, and plume escapes water surface
 High Energy Rate Forming
(Electro-hydraulic/Electric discharge Forming
1. Set up
2. Electrical energy accumulated in the large capacitors
3. Discharge of electrical energy between two electrodes
submersed in the transmission fluid (water)
4. Shock wave forms part, and plume escapes water surface
5. Limited to smaller parts only
 High Energy Rate Forming
(Electromagnetic/Magnetic pulse Forming)
1. Setup in which coil is inserted into tubular work part
surrounded by die
2. energy stored in a capacitor bank is discharged rapidly through
a magnetic coil
3. magnetic forces collapsed work piece over a solid die forming
desired shape
 High Energy Rate Forming
(Electromagnetic/Magnetic pulse Forming)
Honeycomb Structures
Stamping Press and Press Frames
Steps in Manufacturing of Aluminum Can
Cost Comparison for Spinning and Deep Drawing
Characteristics of Sheet-Metal Forming Processes