Proses Manufaktur 1

Sheet Metal Working

1
Content
1 Introduction

2 CUTTING

3 BENDING

4 DRAWING

5 Shapes other than Cylindrical Cups

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Sheet Metalworking Defined

Cutting and forming operations performed on

relatively thin sheets of metal
• Thickness of sheet metal = 0.4 mm to 6 mm
• Thickness of plate stock > 6 mm
• Operations usually performed as cold working

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Sheet and Plate Metal Products
Sheet and plate 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

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Advantages of Sheet Metal Parts

• High strength
• Good dimensional accuracy
• Good surface finish
• Relatively low cost
• For large quantities, economical mass production
operations are available

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Sheet Metalworking Terminology

1. “Punch-and-die”
– Tooling to perform
cutting, bending, and
drawing
2. “Stamping press”
– Machine tool that
performs most sheet
metal operations
3. “Stampings”
– Sheet metal products

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Three Major Categories of Sheet Metal Processes

1. Cutting
◦ Shearing to separate large sheets;
or cut part perimeters or make
holes in sheets

2. Bending
◦ Straining sheet around a straight
axis

3. Drawing
◦ Forming of sheet into convex or
concave shapes

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Content
1 Introduction

2 CUTTING

3 BENDING

4 DRAWING

5 Shapes other than Cylindrical Cups

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Cutting

Shearing between two sharp cutting edges

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Shearing, Blanking, and Punching

Three principal operations in pressworking that cut

sheet metal:

• Shearing
• Blanking
• Punching

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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

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Blanking and Punching
Blanking - sheet metal cutting to separate piece from surrounding stock
• Cut piece is the desired part, called a blank

Punching - sheet metal cutting similar to blanking except cut piece is

scrap, called a slug
• Remaining stock is the desired part

(a) Blanking and (b) punching

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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

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Dies for Sheet Metal Processes
Most pressworking operations performed with conventional
punch-and-die tooling
•The term stamping die sometimes used for high production dies

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Dies for Sheet Metal Processes

(a) Progressive die;

(b) associated strip
development

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Other shearing processes

Lanzing

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Close tolerances and low v

Other shearing processes

Fine blanking

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Close tolerances and low v

 Clearance in Sheet Metal Cutting

Distance between punch cutting edge and

die cutting edge
• Typical values range between 6% and
15% of stock thickness
– If clearance is too small, fracture lines pass each
other, causing double buffing and larger force
– If too large, metal is pinched and bent between
cutting edges and excessive burr results

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 Clearance in Sheet Metal Cutting

• Recommended clearance is calculated by:

c = at
where c = clearance; a = allowance; and
t = stock thickness
– Allowance a is determined according to type
of metal
– Low “c” for soft materials
– High “c” for hard materials
– Typical “a” values for metals range from 0.04
to 0.09

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 Punch and Die Sizes
– Blanking (Blank diameter is controlled)
- For a round blank of diameter, Db
– Diameter of die = blank diameter ( Db)
– Diameter of punch = Db - 2c
where c = clearance

– Punching (Hole diameter is controlled)

- For a round hole of diameter , Dh
– Diameter of punch = hole diameter (Dh )
– Diameter of die = Dh + 2c
where c = clearance

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 Cutting Forces
Important for determining press size (tonnage)
F=StL
where S = shear strength of the metal; t = stock thickness,
L = length of cut edge (contact length) = 2*3.14* R
L is basically perimeter of blank or hole being cut

The above formula is based on fact that entire

punch face is engaged in cutting.
If angled punched is used, cutting force will
reduce.

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 Example Problem

C= At

In blanking. Die size = blank size

Punch size = die size - 2C

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 Example

F=StL

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Content
1 Introduction

2 CUTTING

3 BENDING

4 DRAWING

5 Shapes other than Cylindrical Cups

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

(a) Bending of sheet metal (b) both compression and tensile

elongation of the metal occur in
bending

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Types of Sheetmetal Bending

• V-bending - performed with a V-shaped die

• Edge bending - performed with a wiping die

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V-Bending

• For low production

• Performed on a press brake
• V-dies are simple and inexpensive

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Edge Bending
• For high production
• Pressure pad required
• Dies are more complicated and costly

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 Bend Allowance Formula

where Ab = bend allowance;  = bend angle; R=

bend radius; t = stock thickness; and Kba is factor
to estimate stretching

• If R < 2t, Kba = 0.33

• If R  2t, Kba = 0.50

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Springback in Bending
Springback = increase in included angle of bent part
relative to included angle of forming tool after tool is
removed
• 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 Force

Maximum bending force estimated as follows:

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; D is opening width of a V-die or wiping
die

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Content
1 Introduction

2 CUTTING

3 BENDING

4 DRAWING

5 Shapes other than Cylindrical Cups

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Drawing
Sheet metal forming to make cup-shaped, box-shaped,
or other complex-curved, hollow-shaped parts

Products: beverage cans,

ammunition shells,
automobile body panels

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 Mechanics of Drawing

Bending at Straightening the

Fh: Holding force die and bent sheet,
F: Punch force punch radius stretching

Wall thickness
variation: yes

Wall thinning
maximum at
bottom corner of
cup (max: 25%)

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 Defects in Sheet Drawing

Due to Small Due to Small Due to high Due to high Due to friction and
blank holding Punch force blank holding anisotropy of lack of lubrication
force force material at the sheet/punch
interface

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Content
1 Introduction

2 CUTTING

3 BENDING

4 DRAWING

5 Shapes other than Cylindrical Cups

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Shapes other than Cylindrical Cups

• Square or rectangular boxes (as in sinks),

• Stepped cups,
• Cones,
• Cups with spherical rather than flat bases,
• Irregular curved forms (as in automobile body panels)

• Each of these shapes presents its own unique technical

problems in drawing

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 Ironing
 Makes wall thickness of cylindrical cup more uniform
 Examples: beverage cans and artillery shells

Ironing to achieve a more uniform wall thickness in a drawn cup:

(1) start of process; (2) during process
Note thinning and elongation of walls

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 Embossing
 Used to create indentations in sheet, such as raised (or
indented) lettering or strengthening ribs

Embossing: (a) cross-section of punch and die configuration during

pressing; (b) finished part with embossed ribs

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Guerin Process
Advantages of Guerin Process
 Low tooling cost
 Form block can be made of wood, plastic, or other materials that are
easy to shape
 Rubber pad can be used with different form blocks
 Process attractive in small quantity production

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Several sheet metal parts produced on a turret press, showing variety of hole
shapes possible
(photo courtesy of Strippet, Inc.)

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Power and Drive Systems

• Hydraulic presses - use a large piston and

cylinder to drive the ram
– Longer ram stroke than mechanical types
– Suited to deep drawing
– Slower than mechanical drives
• Mechanical presses – convert rotation of motor
to linear motion of ram
– High forces at bottom of stroke
– Suited to blanking and punching

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Content
1 Introduction

2 CUTTING

3 BENDING

4 DRAWING

5 Shapes other than Cylindrical Cups

6 Sheet Metal Operations Not Performed on Presses

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Sheet Metal Operations Not Performed on Presses

1. Stretch forming
2. Roll bending and forming
3. Spinning
4. High-energy-rate forming processes.

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Stretch Forming
Sheet metal is stretched and simultaneously bent to achieve
shape change

Stretch forming: (1) start of process; (2) form die is pressed into
the work with force Fdie, causing it to be stretched and bent over
the form. F = stretching force

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Roll Bending
Large metal sheets and plates are formed into curved
sections using rolls

Roll bending

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 Roll Forming
Continuous bending process in which opposing rolls produce
long sections of formed shapes from coil or strip stock

Roll forming of a continuous

channel section:
(1) straight rolls
(2) partial form
(3) final form

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Spinning
Metal forming process in which an axially symmetric part is
gradually shaped over a rotating mandrel using a rounded
tool or roller

Conventional spinning: (1) setup at start of process; (2) during

spinning; and (3) completion of process

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High-Energy-Rate Forming (HERF)
Processes to form metals using large amounts of
energy over a very short time

• HERF processes include:

– Explosive forming
– Electrohydraulic forming
– Electromagnetic forming

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 Explosive Forming
Use of explosive charge to form sheet (or plate) metal into a die cavity
• Explosive charge causes a shock wave whose energy is transmitted
to force part into cavity
• Applications: large parts, typical of aerospace industry

Explosive forming:
(1) setup, (2) explosive is detonated, and
(3) shock wave forms part and plume escapes water surface

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 Electromagnetic Forming

Sheet metal is deformed by mechanical force of an

electromagnetic field induced in workpart by an energized coil
• Presently the most widely used HERF process
• Applications: tubular parts

Electromagnetic forming: (1) setup in which coil is inserted into tubular

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workpart surrounded by die; (2) formed part