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18MEPD0 – DESIGN FOR SHEET METAL 18MEPD0 – DESIGN FOR SHEET METAL
MANUFACTURING MANUFACTURING
Course Outcomes
By the end of the course, student will be able to:
1. Explain the working principles of different presses, various sheet
metal cutting operations of pressing processes, basics of shearing
process and types of cutting press tools. (20)
Chapter-5
2. Perform design calculations for cutting force, stripping force, cutting
clearance, strip layout with optimum stock utilization and selection of
Calculation of parameters
3.
press for a given part. (15)
Design a blanking press tool and piercing press tool with bill of
for non-cutting operations
materials for a given part. (20)
4. Explain the various sheet metal non-cutting operations of pressing

5.
processes and types of non-cutting press tools. (10)
Perform design calculations for bending force, blank development,
Prof. M.Karthic, M.E
drawing force, blank size, number of draws and selection of press E-mail: [email protected]
for a given part. (15)
6. Design a drawing press tool with bill of materials for a given part.
2
(20)

5.1 Determination of Blank length for

Chapter-5 bending
Calculation of parameters for
BEND ALLOWANCE:
The bend allowance is the length of the arc of the neutral bending line for a given
degree value.
non-cutting operations
5.1 Determination of Blank length for bending- 1

5.2 Calculation of bending force– 1

5.3 Determination of Blank size for drawing– 1

5.4 Determination of Number of Draws– 1

Calculation of Drawing Force, Press Tonnage and Selection

5.5
of Press - 1
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5.1 Determination of Blank length for 5.1 Determination of Blank length for
bending bending

5.1 Determination of Blank length for 5.1 Determination of Blank length for
bending bending

https://cdn2.hubspot.net/hubfs/3336622/Bend-Allowance.pdf
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5.1 Determination of Blank length for 5.1 Determination of Blank length for
bending bending

Air bending V-Die bending U-Die bending Bottoming Coining

5.1 Determination of Blank length 5.1 Determination of Blank length

for bending for bending
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5.1 Determination of Blank length 5.1 Determination of Blank length

for bending for bending

5.2 Calculation of bending force 5.2 Calculation of bending force

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5.2 Calculation of bending force 5.2 Calculation of bending force

5.2 Calculation of bending force 5.2 Calculation of bending force

Where
UTS = Ultimate
tensile strength
of work piece
L = Length of
bend
t = Thickness of
the work
W = Width of
the die opening
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5.2 Calculation of bending force 5.2 Calculation of bending force

Estimate the force required for a 90 deg bending of St 50 steel of thickness 2

mm in a V die. The length of the bent part is 1 m. Ultimate tensile strength = 500
MPa

k = The factor includes various K = 1.33 for die opening of 8t

factors, including friction = 1.20 for die opening of 16t
= 1.2 to 1.33 for V –die = 0.67 for U bending
= 0.3 to 0.34 for wiping die = 0.33 for a wiping die

W = width between the contact points =

8t for V-bends

5.2 Calculation of bending force 5.2 Calculation of bending force

Calculate the bending force required for a C50 steel 1.5 mm sheet of width 1 m to
be bent in a wiping die. The die radius used is 3 mm. C50 steel, ultimate tensile
strength can be taken as 800 MPa.
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5.2 Calculation of bending force 5.2 Calculation of bending force

5.2 Calculation of bending force 5.2 Calculation of bending force

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5.2 Calculation of bending force 5.3 Determination of Blank size for

drawing

5.3 Determination of Blank size for 5.3 Determination of Blank size for
drawing drawing

https://www.calculatoratoz.com/en/blank-size-for-drawing-operation-calculator/Calc-
8572
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5.3 Determination of Blank size for 5.3 Determination of Blank size for
drawing drawing

5.3 Determination of Blank size for 5.3 Determination of Blank size for
drawing drawing
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5.4 Determination of Number of 5.4 Determination of Number of

Draws Draws
The number of successive draws required is a function of the ratio of the part height h
to the part diameter d, and is given by this formula:
n = h/d
where
n = number of draws; h = part height; d = part diameter
The value of n for the cylindrical cup draw is given in Table 6.1.

5.4 Determination of Number of 5.4 Determination of Number of

Draws Draws
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5.5 Calculation of Drawing Force,

Press Tonnage and Selection of
Press
Drawing force:
Fd,max = n*π*d*t*UTS
Where, Fd,max = Drawing Force (N)
d = Cup Diameter (mm)
t = Sheet Thickness (mm)
UTS = Ultimate Tensile Strength (Mpa)
n = Drawing Co efficient (usually 0.7 to 0.95)

Draw clearance:
Thickness S 1st Draw 2nd Draw Sizing Draw

< 0.4 1.08 S 1.09-1.10 S 1.04-1.05 S

0.4 - 1.27 1.08 - 1.10 S 1.10 - 1.13 S 1.05 - 1.06 S

1.27 - 3.18 1.10 - 1.13 S 1.13 - 1.15 S 1.06 - 1.08 S

S = Material thickness
> 3.175 1.13 - 1.15 S 1.15 - 1.20 S 1.08 - 1.10 S