German Jordanian University

School of Applied Technical Sciences

Department of Industrial Engineering
\ Manufacturing Processes Lab IE0345/IE3250

Student name: ID: 20209103098

Bahaa Hamdan
Section:

Experiment 4: Sheet Metal Forming

• Write your observations after changing the clearance c in the shearing process.
Reducing the clearance between the upper and lower blades increases the shearing force required to cut
the material. This results in a cleaner cut and reduces the amount of burr on the edges of the material.
Increasing the clearance reduces the shearing force required to cut the material but can result in a rough
cut and increase the burr on the edges of the material.

• Estimate the force required in shearing a rectangular sheet along a length of 20 centimeters
through 0.7 mm thick of AISI 1020 mild steel (UTS=420Mpa)
F = 0.7(UTS)tL
F = 0.7*420*0.7*0.2
F = 41.16 KN
• How a shearing process such as the previous one could be easily manually done using bench
shear.
Due to the inclined blade in cutting tools, enhanced cutting performance and improved cut edge quality
can be achieved. This is attributed to the blade's capacity to reduce the required force and produce a
smoother cut.
A bench shear, commonly employed in metalworking to cut various materials like sheet metal, follows
these steps for the shearing process:
1. Secure the material on the bench shear's table or cutting bed.
2. Adjust the blade gap by turning the adjusting screw on the bench shear's blade assembly to the
appropriate distance for the material.
3. Ensure the material aligns with the bench shear's blade, maintaining a straight and correct angle.
4. Lower the bench shear's blade onto the material using the provided lever or foot pedal.
5. Apply pressure to execute the cut, using force on the lever or foot pedal based on the bench shear
type.
6. Upon completing the cut, release pressure on the blade and return it to its initial position.
7. Remove the cut material from the bench shear's cutting bed, and repeat the process as necessary for
additional cuts.
• For the bended specimens, find Rf and αf then calculate the bend allowance, spring back factor 𝐾𝑠
in each case:
Test NO. Material Thickness Clearance Angle
1 Steel 2 0 45
2 Steel 2 0 90
3 Steel 0.7 0 90
4 Aluminum 2 0 90
5 Steel 2 2 90

Test NO. Rf αf Bend allowance Spring Back factor

1 4.865 2.380 13.9587 0.142
2 1.308 1.59 3.67 -0.077
3 1.391 1.645 3.933 -0.065
4 0.720 1.571 2.702 -0.311
5 2.306 1.652 5.46 0.120

K=0.5
Sample of calculation:
1- For Bend Allowance:
𝐿𝑏 = ∝ (𝑅 + 𝑘𝑡) = 2.380(4.865 + (0.5 × 2)) = 13.9587
2- For Spring Back Factor:
𝐾𝑠 = Rf−αf/ Bend allowance=4.865-2.380/13.9587=0.142

• Discuss the factors that were changed in the bending experiment and their effects.
 Test No. 2 and Test No. 4 have negative spring back factors, indicating overbending. Adjustments in
the bending process may be needed to reduce spring back.
Test No. 5 has a positive spring back factor suggesting under bending. Considerations for increasing
the bend allowance or adjusting the bending parameters may be necessary.
The choice of material and its thickness has a noticeable impact on the spring back factor. Aluminum
(Test No. 4) exhibits a higher negative spring back factor compared to steel samples (Test No. 1, 2, and
5).
Varying clearance (Test No. 5) also influences the spring back factor. The positive spring back factor
indicates potential under bending due to the increased clearance
• Describe the surface at the outer bend surface (flaws, cracks, texture)

Test NO. Outer bend Surface

1 Flaws
2 Cracks
3 Flaws
4 Texture
5 Cracks

• Why is it more important to check the outer bend surface rather than the inner one?

As the external surface of the object is under tension, it is more susceptible to cracking,
while the internal surface experiences compression