Sheet Metal Presswork

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 Different types of presses

C-Frame Mechanica Press H-Frame Hydraulic Press

 Types of press tools

Simple tool Compound tool

Progressive tools stages

Cutting Operation Observations
F = S t L, where S = shear strength of metal; t = stock thickness, and L = perimeter length of blank or hole being cut.
In a typical rolling, the thickness of a metal plate is reduced by two rotating mills. The
starting work material in rolling is a metal plate. On the other hand, sheet metalworking
operations are performed on relatively thin metal sheets.

Examples:

It is required to produce 50 mm diameter blanks from 2 mm thick low-carbon steel.

If a clearance allowance of 6% is chosen, then
diameter of die = diameter of blank = 50 mm, Dpunch = Dblank - 2c
clearance per side, c=at, = 6% of 2 mm = 0.12 mm
clearance on diameter is, therefore, 2 × 0.12 mm = 0.24 mm
Thus, the diameter of the punch is smaller than the die by this amount; therefore, the
diameter of the punch = 50 mm − 0.24 mm = 49.76 mm

Punching 20 mm diameter holes in 1.5 mm thick copper is required. If a clearance

allowance of 4% is chosen, then the diameter of punch = diameter of hole = 20 mm
Dhole=Dpunch+2c,
clearance per side, c=at, = 4% of 1.5 mm = 0.06 mm,
clearance on diameter is therefore 2 x 0.06 mm = 0.12 mm
Thus, the diameter of the die is larger than the punch by this amount; therefore, the
diameter of the die = 20 mm + 0.12 mm = 20.12 mm
c = a*t
where c = clearance; a = clearance allowance; and t = stock thickness
• Allowance a is determined according to the type of metal
Blanking – Punching- Exercise

A blanking die is designed to blank the part outline in the

figure below. The material is 4 mm thick stainless steel
(the allowance for the stainless steel is a = 0.075).
Determine the dimensions of the blanking punch and the
die opening.

Solution:

Since a = 0.075, the clearance is given by,

c = a*t = 0.075 (4) = 0.3 mm.

Blanking die dimensions: the same as for the part in the figure:
L = 85 mm w = 50 mm t = 25 mm s = 25 mm

Blanking punch dimensions:

Blanking Punch = Db -2c
Length L = 85 - 2(0.3) = 84.4 mm
Width w = 50 - 2(0.3) = 49.4 mm
Top and bottom t widths = 25 - 2(0.3) = 24.4 mm
The s = 25- 2(0.3) = 24.4 mm
A compound die will blank and punch a large washer out of 6061ST aluminium alloy (the allowance is a = 0.06), sheet stock
3.50 mm thick. The washer’s outside diameter is 50 mm, and the inside diameter is 15 mm. Determine (a) the punch and
die sizes for the blanking operation and (b) the punch and die sizes for the punching operation.

Solution:

Since a = 0.06, the clearance is given by,

c =a*t = 0.06 (3.5) = 0.21 mm

(a) Blanking punch diameter = Db - 2c = 50 - 2(0.21) = 49.58 mm

Blanking die diameter = Db = 50 mm

(b) Punching punch diameter = Dh = 15 mm

Punching die diameter = Dh + 2c = 15 + 2(0.21) = 15.42 mm
A blanking operation will be performed on 2 mm thick cold rolled steel. The part is
circular with diameter = 75 mm.
Determine: a) the appropriate punch and die sizes for this operation if the
allowance for the cold rolled steel is a = 0.075. b) the blanking force required if the
steel has a shear strength = 325 MPa and the tensile strength is 450 MPa

Solution:

(a) Since a = 0.075, the clearance is given by,

c = a*t = 0.075 (2) = 0.15 mm.

Thus, the Punch diameter Dh is calculated as

Dh = Db - 2c = 75.0 - 2(0.15) = 74.70 mm. And the Die diameter is Db = 75 mm.

(b) the blanking force is given by

F = StL

The thickness of the metal stock t is given by the problem as t = 2 mm

The length of the cut edge is calculated as:

L = πD = 75π = 75π mm

Thus, the blanking force is

F = 325 (2) (75π) = 153.153 kN

F=0.7Ts.tL

F= 0.7*450*2*75π

F= 148.440 kN

F = StL ≈ 0.7Ts.tL
Deep Drawing feasibility
 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏
𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 =
𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝ℎ
𝐷𝐷𝑏𝑏
𝐷𝐷𝑅𝑅 = < 2 equation 1
𝐷𝐷𝑝𝑝

𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 − 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝ℎ
𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 =
𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏
𝐷𝐷𝑏𝑏 −𝐷𝐷𝑝𝑝
𝑅𝑅 = < 50% equation 2
𝐷𝐷𝑏𝑏
𝑡𝑡ℎ𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖
𝑡𝑡ℎ𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑡𝑡𝑡𝑡 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 =
𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏
𝑡𝑡
𝑡𝑡𝐷𝐷𝑟𝑟 = > 1% equation 3
𝐷𝐷𝑏𝑏
Deep drawing
A cup is to be drawn in a deep drawing operation. The height of the cup
is 75 mm, and its inside diameter = 100 mm. The sheet metal thickness
= 2 mm. If the blank diameter = 225 mm, determine (a) drawing ratio,
(b) reduction, and (c) thickness-to-diameter ratio. (d) Does the operation
seem feasible?
Press Brake Bending

• Form sheet into a variety of shapes.

• RAM, which moves vertically to press against the bed.
• Punches are bolted onto RAM and they match die fastened to bed.
• P.B. can be mechanically or hydraulically operated.
• Die sets are inexpensive - today 'urethane' is used as male (die) half - accuracy and repeatability is excellent.

Two common bending methods are V-bending and edge-bending.

Bending Allowance:

The sheet metal of thickness (t) is bent through a bend angle A. This results in a sheet metal part with an included angle A’, where A + A’ =
180°. The bend is made over the width (w) of the workpiece. The length of the neutral axis needs to be determined to account for stretching
of the final bend. This length is called the bend allowance and is estimated as follows:
Spring-back:

When the bending pressure is removed

at the end of the deformation operation,
elastic energy remains in the bent part,
causing it to recover partially toward its
original shape. This elastic recovery is
called spring back, defined as the
increase in the included angle of the bent
part relative to the included angle of the
forming tool after the tool is removed.

Tube Bending:
• Round tubing used for fuel lines, plumbing supplies, cooling and heating coils and car muffler requires bending.
• Both square and round tubing used for furniture may require bending.
• To form/bend this material, special tube-bending machines are available.
• N.C. tube-benders will, at command of the
punched tape, measure to length, bend to proper
angle, rotate the part if necessary, clamp,
measure and make the next bend and cut off
automatically.
Materials suitable for drawing:
• Low carbon steel
• Aluminium
• Copper Alloy
• Stainless steels

Lubrication:
• Lubricants or drawing compounds are used to reduce friction forces.
• Lubrication is necessary as sliding friction is great and pressure welding (galling) may occur.
• Lubricant may be brushed /sprayed on or sheets may be pre-lubricated.
• Lubricants used:

Oil, soap solution, grease, wax, moly disulfide and water – soluble oil
The tooling in the Guerin Process is made of a thick rubber pad, which is confined in a steel container.
As the ram descends, the rubber gradually surrounds the sheet, applying pressure to deform it to the
shape of the form block. The form block can be made of wood, plastics, or other materials that are easy
to shape. This type of tooling is relatively low-cost.
Sheet Metal Products • Economical mass production for large
quantities
Sheet metal parts for consumer and industrial
products, such as
– Automobiles and trucks
– Airplanes
– Railway cars and locomotives
– Farm and construction equipment
– Small and large appliances
– Office furniture
– Computers and office equipment

Advantages of Sheet Metal Parts

• High strength
• Good dimensional accuracy
• Good surface finish
• Relatively low cost