lecture05 – sheet metal working

Introduction to sheet metal working

• Sheet metalworking - cutting and forming operations
performed on sheet metals.
• Sheet metals are thin sheets ( < 6.25mm) of wrought metals,
formed by rolling, are used to produce thin-walled parts.
• The tooling is called punch and die mounted on machine tools
called presses.
• Press working or press forming is used for general sheet-
forming operations, as they are performed on presses using a
set of dies
Introduction to sheet metal working (cont.)

• A sheet-metal part produced in presses is called a stamping

• A press working or press forming is also known as stamping.
• Common sheet metal materials
– Carbon steel, Aluminum, Stainless steel, etc.
• Low-carbon steel has low cost and good strength and
formability characteristics
• Sheet-metal processing is usually performed at room
temperatures (cold working)
Introduction to sheet metal working (cont.)
Introduction to sheet metal working (cont.)

• Examples of parts made by stamping are can openers, fan

blades, pulleys, ash trays, razor blades, buckles, kitchen
utensils, cans, bottle caps, automobile and truck bodies,
airplanes, office furniture, computers and office equipment,
and other items.
Introduction to sheet metal working (cont.)
 Stamping
• Stamping can be divided into two broad
categories of press operations:
1. Shearing or cutting operations – such as
punching, piercing
2. Non-shearing operations such as forming
drawing, bending
 Shearing (cutting) operations
• Shearing (cutting) operations is performed by
exceeding the shear strength of the material
• Shearing (cutting) is used to:
– Produce intermediate blanks
– Produce features
– Separate/remove part from strip of sheet metal
– Trim/slit a part for size control
Shearing/cutting operations (cont.)
• The process by which a hole is punched involves three phases:
Plastic Deformation, Penetration, and Fracture

• The edges are not smooth and perpendicular to the plane of the
sheet
 Shearing/cutting operations (cont.)
Roll Over + Burnish = Penetration
Shearing/cutting operations (cont.)
• Geometrical features of mechanically sheared/cut edges
– Roll Over – Flow of material around the punch and die
• The larger the clearance the greater the roll over
– Burnish – The rubbed or “cut” portion of the edge
• The sharper the punch the wider the burnish
– Fracture – The angled surface where the material separates from
the parent material
– Burr – The very sharp projection caused by a dull cutting on the
punch or die.
– General Rules: The more dull the tool the greater the burr. The
softer the material the greater the burr.
*These characteristics are evident on both the hole and slug
 Shearing/cutting operations (cont.)
• Processing parameters in shearing are
– The shape of the punch and die
– The speed of punching (Extent of the deformation zone
depends on the punch speed)
– Lubrication ( Friction between the punch and the
workpiece can increase punch force)
– The clearance, c, between the punch and the die
 Shearing/cutting operations (cont.)
• Die clearance
Shearing/cutting operations (cont.)
Proper Clearance
Fracture lines meet

- Punching forces are balanced,

- Maximum piece part quality and
tool life

Fracture lines do not meet

- Secondary shear cracks,

- Extra energy required,
- Higher tool wear (dies wear quicker)

Extra energy does not disappear,

but is converted into heat !!
Shearing/cutting operations (cont.)
• Proper Clearance
– Too Big – Blank ends up with roll-
over and/or a crown effect.
– Too Small – Results in large
stripping force and secondary
shear. Secondary shear is when
the fracture propagating from the
punch misses the fracture
propagating from the die.
– When proper clearance exists the
fractures meet, which yields a
preferable break edge.
As the tool wears and the clearance between the punch and die grow the material
will begin to experience more tensile deformation and less shear deformation prior
to fracture
 Shearing/cutting operations (cont.)
• Burnish Percentages by Material

Mild cold rolled steel  30%

5052 H32 Aluminum  60%
304 Stainless 15%
Brass or Copper  55%
 Shearing/cutting operations (cont.)
• Blanking – Material removed is the work-piece
• Piercing – Material removed is scrap
• Lancing – No metal removed, cutting and bending
• Cut-off/Parting - Separating parts or reducing scrap
strip size
• Notching – Removing material from the outer edges
of the strip
• Shaving – Removing the break edge
• Trimming – Removing “Flash” from parts
 Punching Techniques
• Blanking
– When the slug becomes the
“good” or the “saved part”
– Die Size = Desired Blank Size
(no Slug Free dies !)
– Punch Size = Die Size – Total
Clearance

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 Shearing/cutting operations (cont.)
• Piercing
– The slug is scrap. The
interior of the sheet is
the product.
– Punch Size = Desired Hole
Size
– Die Size = Punch Size + Total
Clearance

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 Shearing
• Sheet metal cutting operation along a straight line between
two cutting edges
• Typically used to cut large sheets into smaller sections for
subsequent operations

Figure ‑ Shearing operation:

(a) side view of the shearing operation
(b) front view of power shears equipped with inclined upper cutting blade Symbol
v indicates motion
 Punch and Die Sizes for Blanking and
Punching
• For a round blank of diameter
Db :
– Blanking punch diameter =
Db ‑ 2c
– Blanking die diameter = Db
– where c = clearance
• For a round hole of diameter
Dh :
– Hole punch diameter = Dh
– Hole die diameter = Dh + 2c
– where c = clearance
Figure ‑ Die size determines blank size Db; punch
size determines hole size Dh.; c = clearance
 Clearance in Sheet Metal Cutting
• Distance between the punch and die
• Typical values range between 4% and 8% of stock thickness
– If too small, fracture lines pass each other, causing double
burnishing and larger force
– If too large, metal is pinched between cutting edges and
excessive burr results
• Recommended clearance can be calculated by: c = at
where c = clearance; a = allowance; and
t = stock thickness
• Allowance a is determined according to type of metal

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Allowance a for Three Sheet Metal Groups

Metal group a
1100S and 5052S aluminum alloys, all 0.045
tempers
2024ST and 6061ST aluminum alloys; brass, 0.060
soft cold rolled steel, soft stainless steel
Cold rolled steel, half hard; stainless steel, half 0.075
hard and full hard

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 Shearing/cutting operations (cont.)

• DIE CLEARANCES - Percent of Material Thickness

Material type minimum  optimum  maximum
cold rolled steel  10%  15%  20%
Carbon steel  12%  18%  %24
Stainless steel   15%  20% 25%
E.G. mild steel    12% 18% 24%
5052 H32 aluminum   5% 10%  15%
T4 aluminum    12% 18% 24%
T6 aluminum   15% 20%  25%
Brass    6% 12% 16%
1/2 hard copper   8% 12%  16%
 Angular Clearance
• Purpose: allows slug or blank to drop through die
• Typical values: 0.25 to 1.5 on each side

Figure 20.7 ‑ Angular

clearance
 Shearing
Punch Force
• Important for determining press size (tonnage)
• Maximum punch force, F, can be estimated from

F  0.7TLUTS 
T = sheet thickness
L = total length sheared
UTS = ultimate tensile strength of the material
• Friction between the punch and the workpiece can
increase punch force
 Shearing
EXAMPLE 16.1
Calculation of Punch Force
Estimate the force required for punching a 25-mm
diameter hole through a 3.2-mm thick annealed titanium-
alloy Ti-6Al-4V sheet at room temperature.

Solution
UTS for this alloy is 1000 MPa, thus

F  0.7 32    251000   0.18 MN

 Bending
Straining sheetmetal around a straight axis to take
a permanent bend

Figure 20.11 ‑ (a) Bending of sheet metal

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Metal on inside of neutral plane is compressed, while
metal on outside of neutral plane is stretched

Figure 20.11 ‑ (b) both compression and tensile elongation of the metal
occur in bending
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 Types of Sheet metal Bending –
V-Bending
• performed with a V‑shaped die
• For low production
• Performed on a press brake
• V-dies are simple and inexpensive

Figure 20.12 ‑
(a) V‑bending

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• Edge Bending - performed with a wiping die
• For high production
• Pressure pad required
• Dies are more complicated and costly

Figure 20.12 ‑ (b) edge bending

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 Stretching during Bending
• If bend radius is small relative to stock
thickness, metal tends to stretch during
bending
• Important to estimate amount of stretching,
so that final part length = specified dimension
is maintained
• Problem: to determine the length of neutral
axis of the part before bending

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Bend Allowance
 Bend Allowance Formula

A
BA  2 (R  K bat )
360

where BA = bend allowance; A = bend angle;

R= bend radius; t = stock thickness; and Kba=
stretch
• If R < 2t, Kba = 0.33
• If R  2t, Kba = 0.50
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• An L-shaped part is to be bent in a V-bending operation from a
flat blank 4.0 inches by 1.5 inches that is 5/32 inch thick. The
bend of 90° is to be made in the middle of the 4-inch length.
(a) Determine the dimensions of the two equal sides that will
result after the bend, if the bend radius = 3/16 inch. (b) Also,
determine the length of the part's neutral axis after the bend.
Solution: (a) R/t = (3/16)/(5/32) = 1.2. Therefore, Kba = 0.33
BA = 2p(90/360)(0.1875 + 0.33 x 0.15625) = 0.3756 in.
Dimensions (lengths) of each end = 0.5(4.0 - 0.3756) = 1.8122 in.
(b) BA = 2p(90/360)(0.1875 + 0.5 x 0.15625) = 0.4173 in.
Therefore, the length of the neutral axis of the part will be
2(1.8122) + 0.4173 = 4.0417 in.
 Springback in Bending
Springback = increase in included angle of bent part relative to included angle
of forming tool after tool is removed
Compensation for
Springback
Springback is
compensated for by
overbending the part

• Reason for springback:

– When bending pressure is removed, elastic energy remains in
bent part, causing it to recover partially toward its original shape

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 Bending Analysis
A  Ab
Spring back, SB 
Ab

where A’ = included angle of sheet-metal part

A’b = included angle of bending tool

K bfwTwt
= width
2 of sheet-metal
Bending force F  D = die opening dimension
D
Kbf = 1.33 V-bending
Kbf = 0.33 edge bending
 Bending Force

Maximum bending force estimated as follows:

K bf TSwt 2
F
D

where F = bending force; TS = tensile strength of sheet metal; w = part width in

direction of bend axis; and t = stock thickness. For V- bending, Kbf = 1.33; for edge
bending, Kbf = 0.33

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• A sheet metal part 3.0 mm thick and 20.0 mm long is
bent to an included angle = 60° and a bend radius =
7.5 mm in a V-die. The metal has a tensile strength =
340 MPa. Compute the required force to bend the
part, given that the die opening = 15 mm.
• Solution: For V-bending, Kbf = 1.33.
F = Kbf(TS)wt2/D = 1.33(340)(20)(3)2/15 = 5426N
Figure 20.14 ‑ Die opening dimension D: (a) V‑die, (b) wiping die

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 Drawing
Sheet metal forming to make cup‑shaped,
box‑shaped, or other complex‑curved,
hollow‑shaped parts
• Sheet metal blank is positioned over die cavity
and then punch pushes metal into opening
• Products: beverage cans, ammunition shells,
automobile body panels

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Drawing
c = Clearance
Db = blank diameter
Dp = Punch diameter
Rd = die corner
radius
Rp = Punch corner
radius
F = drawing force
Fh = holding force
 Deep Drawing

Initial step bending of edge straightening of side wall

Thinning and drawing final cup shape

 Clearance in Drawing
• Sides of punch and die separated by a
clearance c given by:
c = 1.1 t
where t = stock thickness
• In other words, clearance = about 10% greater
than stock thickness

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 Drawing Ratio DR
Most easily defined for cylindrical shape:

Db
DR 
Dp

where Db = blank diameter; and Dp = punch

diameter
• Indicates severity of a given drawing operation
– Upper limit = 2.0

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 Reduction r

• Again, defined for cylindrical shape:

Db  Dp
r
Db

• Value of r should be less than 0.50

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 Thickness‑to‑Diameter Ratio

Thickness of starting blank divided by blank

diameter
Thickness-to-diameter ratio = t/Db
• Desirable for t/Db ratio to be greater than 1%
• As t/Db decreases, tendency for wrinkling
increases

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 Drawing Analysis
Db
Drawing force, F  D p tT (  0.7) , max. at 1/3 stroke.
Dp

h b p 
Holding force, F  0.015Y D 2  ( D  2.2t  2 R ) 2
d 
Holding pressure may be set at 0.015 of the yield strength
T = Tensile strength, Y = Yield strength, Rd = die corner radius
• A deep drawing operation is performed in which the inside of the
cylindrical cup has a diameter = 4.0 inches and a height = 2.5 inches. The
stock thickness = 1/8 inch, and the starting blank diameter = 7.5 inches.
Punch and die radii = 5/32 inch. The metal has a tensile strength = 60,000
lb/in2 and a yield strength = 30,000 lb/in2. Determine: (a) drawing ratio,
(b) reduction, (c) drawing force, and (d) blankholder force.
• Solution: (a) DR = 7.5/4.0 = 1.875
(b) t/D = 0.125/7.5 = 0.01667 = 1.667%
(c) F = pDpt(TS)(D/Dp - 0.7) = p(4)(0.125)(60,000)(7.5/4 - 0.7) = 110,756 lb.
(d) Fh = 0.015Yp(D2 - (Dp + 2.2t + 2Rd)2)
Fh = 0.015(30,000)p(7.52 - (4 + 2.2 x 0.125 + 2 x 0.15625)2) =
0.015(30,000)p(7.52 - 4.58752) = 49,770 lb
 Drawing Analysis
• Blank diameter can be calculated from the conservation of
volume based on the final volume of the part.
• If the limits on the drawing ratio, reduction and thickness-to-
diameter ratio are exceeded, the blank must be drawn in
steps or having annealing between the steps.
• Process optimization:
– Punch and die corner radii
– friction
– depth of draw (per step)
– material characteristics
 Blank Size Determination
• For final dimensions of drawn shape to be
correct, starting blank diameter Db must be
right
• Solve for Db by setting starting sheet metal
blank volume = final product volume
• To facilitate calculation, assume negligible
thinning of part wall

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Figure 20.30 ‑ Components of a punch and die for a blanking operation

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Figure 20.31 ‑
(a) Progressive die;
(b) associated strip
development

ISE 316 - Manufacturing Processes

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 Tube Bending

Stretch bending

Drawing bending

Compression bending

R/D  3.0 with mandrel

R/D  1.5 without mandrel