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    L21 - Sheetmetal

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    swap d
    The document discusses various sheet metal forming processes including cutting, bending, drawing, spinning, and high-energy forming. Key cutting operations include shearing, blanking, punching, and fine blanking. Important parameters for bending include the bend allowance, springback, and bending force. Deep drawing has limits on the drawing ratio, reduction, and thickness-diameter ratio to prevent defects like wrinkling or tearing. Other forming methods covered are ironing, corrugating, lancing, roll forming, and tube bending.

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    L21 - Sheetmetal

    Uploaded by

    swap d
    10 views28 pages
    The document discusses various sheet metal forming processes including cutting, bending, drawing, spinning, and high-energy forming. Key cutting operations include shearing, blanking, punching, and fine blanking. Important parameters for bending include the bend allowance, springback, and bending force. Deep drawing has limits on the drawing ratio, reduction, and thickness-diameter ratio to prevent defects like wrinkling or tearing. Other forming methods covered are ironing, corrugating, lancing, roll forming, and tube bending.

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    The document discusses various sheet metal forming processes including cutting, bending, drawing, spinning, and high-energy forming. Key cutting operations include shearing, blanking, punching, and fine blanking. Important parameters for bending include the bend allowance, springback, and bending force. Deep drawing has limits on the drawing ratio, reduction, and thickness-diameter ratio to prevent defects like wrinkling or tearing. Other forming methods covered are ironing, corrugating, lancing, roll forming, and tube bending.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    10 views28 pages

    L21 - Sheetmetal

    Uploaded by

    swap d
    The document discusses various sheet metal forming processes including cutting, bending, drawing, spinning, and high-energy forming. Key cutting operations include shearing, blanking, punching, and fine blanking. Important parameters for bending include the bend allowance, springback, and bending force. Deep drawing has limits on the drawing ratio, reduction, and thickness-diameter ratio to prevent defects like wrinkling or tearing. Other forming methods covered are ironing, corrugating, lancing, roll forming, and tube bending.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 28

    MECH152-L21 (1.

    0) - 1

    Sheet Metalworking
    MECH152-L21 (1.0) - 2

    Cutting Operations
    Shearing by two sharp cutting edges.
    Plastic deformation penetration
    fracture
    MECH152-L21 (1.0) - 3

    Shearing, Blanking and Punching


    Shearing - Cutting on sheet-metal with
    straight edges.
    Blanking - Cutting sheet-metal with a closed
    contour.
    Punching - Making holes on sheet-metal.
    MECH152-L21 (1.0) - 4

    Sheet-metal Cutting
    c = at
    c = clearance
    a = allowance
    t = thickness

    Blanking:
    Blanking punch dia. = Db- 2c
    Blanking die dia. = Db

    Punch
    Hole punch dia. = Db
    0.25 to 1.5 Hole die dia. = Db+ 2c
    MECH152-L21 (1.0) - 5

    Sheet-metal Cutting

    Small clearance

    Cutting force = StL


    S = Shear strength of sheet-metal
    t = Sheet-metal thickness
    L = Length of cutting edge
    or, Cutting force = 0.7TtL Large clearance
    T = Ultimate tensile strength of sheet-metal
    MECH152-L21 (1.0) - 6

    Sheet-metal Cutting Operations


    Cut-off

    Parting

    Slotting Perforating Notching / Seminotching


    MECH152-L21 (1.0) - 7

    Sheet-metal Cutting Operations


    Fine blanking -
    close tolerances
    and smooth
    edges in one
    step.

    Trimming - Cutting operation to remove excess metal


    Shaving - Shearing with very small clearance to obtain
    accurate dimensions., secondary or finishing operation.
    MECH152-L21 (1.0) - 8

    Bending

    V- bending Edge - bending


    MECH152-L21 (1.0) - 9

    Bending Analysis
    BA = 2  A( R + Kbat ) / 360
    where BA = bending allowance, A = bend angle, R = bend radius, t = stock
    thickness, Kba = stretch factor.
    For R< 2t, Kba= 0.33 ; for R 2t, Kba= 0.5.

    Spring back,
    A  Ab
    SB 
    ofb sheet-metal part
    where A’ = include angle A
    A’b = include angle of bending tool
    w = width of sheet-metal
    Bending force D = die opening dimension
    K Twt 2
    Kbf = 1.33 V-bending
    bf
    Kbf = 0.33 F  bending
    edge D
    MECH152-L21 (1.0) - 10

    Bending Analysis

    Spring back

    Die-opening
    dimension
    MECH152-L21 (1.0) - 11

    Bending Operations

    Straight flanging Stretch flanging Shrink flanging

    Hemming Seaming Curling


    MECH152-L21 (1.0) - 12

    Bending Operations

    Channel bending U-bending air-bending

    Offset-bending Corrugating Tube forming


    MECH152-L21 (1.0) - 13

    Drawing
    c = Clearance
    Db = blank diameter
    Dp = Punch diameter
    Rd = die corner
    radius
    Rp = Punch corner
    radius
    F = drawing force
    Fh = holding force
    MECH152-L21 (1.0) - 14

    Deep Drawing

    Initial step bending of edge straightening of side wall

    Thinning and drawing final cup shape


    MECH152-L21 (1.0) - 15

    Drawing Analysis
    Db
    Drawing ratio, DR   2.0
    Dp
    where Db = blank diameter
    Dp = punch diameter
    t = thicknessDofthe
    D p starting blank
    b
    Reduction, r  D  0.5
    p

    Thickness to diameter ratio, t / Db  1%


    Db
    Drawing force, F  D p tT (  0.7), max. at 1/3 stroke.
    D p
    F
    Holding force, h  0. 015Y D 2
    b

     ( D p  2 .2t  2 Rd ) 2

    Holding pressure may be set at 0.015 of the yield strength
    T = Tensile strength, Y = Yield strength, Rd = die corner radius
    MECH152-L21 (1.0) - 16

    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
    MECH152-L21 (1.0) - 17

    Drawing Defects

    a) Wrinkling in flange - small holding force


    b) Wrinkling in the wall - insufficient holding force,
    wrinkling initially occurring on the flange.
    c) Tearing - high stress, sharp die radius
    d) Earing - anisotropy of the material
    e) Surface scratches - Die or punch not having a smooth
    surface, insufficient lubrication
    MECH152-L21 (1.0) - 18

    Other Sheet-metal Operations


    Ironing - squeezing and
    drawing in conjunction
    Corning & Embossing - to
    produce surface details
    Lancing - combination of
    cutting and forming
    MECH152-L21 (1.0) - 19

    Other Sheet-metal Operations


    Rubber forming processes:
    Guerin process - low cost,
    small volume, pressure
    up 10 MPa.
    Hydroforming - Higher
    pressure, up to 100 MPa.
    MECH152-L21 (1.0) - 20

    Dies

    Components of a punch and die for blanking operation


    MECH152-L21 (1.0) - 21

    Dies

    Progressive dies
    and final part
    MECH152-L21 (1.0) - 22

    Press
    crankshaft Knuckle joint
    eccentric

    Press are driven mechanically or


    hydraulically.
    MECH152-L21 (1.0) - 23

    Stretch Forming

    Stretching and forming with a die at the same time.


    MECH152-L21 (1.0) - 24

    Roll Forming
    Similar to the
    the rolling
    process but
    working on
    sheet-metal or
    tubes.
    MECH152-L21 (1.0) - 25

    Spinning

    Conventional
    spinning

    Shear spinning - thinning


    and bending occur at the
    same time.
    MECH152-L21 (1.0) - 26

    Spinning

    Tube spinning - similar to shear spinning but working on a


    tube.
    MECH152-L21 (1.0) - 27

    High Energy Forming

    Explosive forming
    Electrohydraulic forming
    Electromagnetic forming
    MECH152-L21 (1.0) - 28

    Tube Bending

    Stretch bending

    Drawing bending

    Compression bending

    R/D  3.0 with mandrel


    R/D  1.5 without mandrel

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