Lecture # 6

12 July 2021

Dr. A. Upadhyaya TA201P: Introduction to Manufacturing Processes

 • Deformation Processing – III
o Sheet Metal Working

Dr. A. Upadhyaya TA201P: Introduction to Manufacturing Processes

Sheet Metal Working

Slides sourced from the book

Introduction to Manufacturing Processes ,
Mikell P. Groover, 4th ed., J. Wiley Pub, 2011
ISBN: 978-0-470-63228-4
 SHEET METALWORKING
• Cutting Operations
• Bending Operations
• Deep Drawing
• Other Sheet Metal Forming Operations
• Dies and Presses for Sheet Metal Processes
• Sheet Metal Operations Not Performed on Presses
• Bending of Tube Stock
 Sheet Metalworking Defined
• Cutting and forming operations performed on
relatively thin sheets of metal
• Thickness of sheet metal = 0.4 mm (1/64 in) to 6
mm (1/4 in)
• Operations usually performed as cold working
 Sheet Metal Products
• Sheet and plate metal parts for consumer and
industrial products such as
o Automobiles and trucks
o Airplanes
o Railway cars and locomotives
o Farm and construction equipment
o Small and large appliances
o Office furniture
o Computers and office equipment
 Advantages of Sheet Metal Parts

• High strength

• Good dimensional accuracy

• Good surface finish

• Relatively low cost

 Sheet Metalworking Terminology

1. “Punch-and-die”
– Tooling to perform cutting, bending, and deep-
drawing
2. “Stamping press”
– Machine tool that performs most sheet metal
operations
3. “Stampings”
– Sheet metal products
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. Deep Drawing
– Forming of sheet into convex or concave shapes
Cutting: Shearing between two sharp cutting edges

(1) just before the (2) punch begins to push into work,
causing plastic deformation
punch contacts work
(3) punch compresses and (4) fracture is initiated at the
penetrates into work causing a opposing cutting edges which
smooth cut surface separates the sheet
 Shearing, Blanking, and Punching

3 principal operations in pressworking that cut sheetmetal:

• Shearing

• Blanking

• Punching
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

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
 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
(a) Blanking and (b) punching
 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
 Clearance in Sheet Metal Cutting

• Recommended clearance can be calculated by:

c = at
where c = clearance (mm); a = allowance; and t =
stock thickness (mm)

• Allowance a is determined according to type of

metal
 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
 Punch and Die Sizes for Blanking and Punching
For a round blank of diameter Db: For a round hole of diameter Dh:
Blanking punch diameter = Db -2c Hole punch diameter = Dh
Blanking die diameter = Db Hole die diameter = Dh + 2c
where c = clearance where c = clearance

Die size determines blank size Db; punch size determines hole size Dh; c = clearance
 Angular Clearance
Purpose: allows slug or blank to drop through die
• Typical values: 0.25 to 1.5 on each side
 Cutting Forces

Important for determining press size (tonnage)

F = S t L or F= 0.7 t L

where S = shear strength of metal (MPa)

 = tensile strength (MPa)
t = stock thickness (mm), and
L = length of cut edge (mm)
 Bending
Straining sheetmetal around a straight axis to
make a permanent bend
Metal on inside of neutral plane is compressed,
while metal on outside of neutral plane is stretched

(b) both compression and tensile elongation of the metal occur in

bending
 Types of Sheetmetal Bending
• V bending - performed with a V-shaped die

• Edge bending - performed with a wiping

die
 V-Bending
• For low production
• Performed on a press brake
• V-dies are simple and inexpensive
 Edge Bending
• For high production
• Pressure pad required
• Dies are more complicated and costly
 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
• Problem: to determine the length of neutral
axis of the part before bending
 Bend Allowance Formula
A
BA  2 ( R  K ba t )
360

where
BA = bend allowance; A = 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
 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
Springback in bending shows itself as a decrease in bend angle
and an increase in bend radius: (1) during bending, the work is
forced to take the radius Rb and included angle Ab' of the
bending tool (punch in V-bending), (2) after punch is removed,
the work springs back to radius R and angle A'
 Bending Force
Maximum bending force estimated as follows:

K bf wt  2

F
D
where F = bending force (N); = tensile strength of sheet
metal (MPa); w = part width in direction of bend axis
(mm); and t = stock thickness. For V- bending, Kbf =
1.33; for edge bending, Kbf = 0.33
Die opening dimension D: (a) V-die, (b) wiping die
 Deep-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
Stages in Deformation of the Workpiece during Deep Drawing
Drawing of a cup-
shaped part:
(1) start of operation
before punch
contacts work
(2) near end of
stroke

(b) Corresponding
workpart:
(1) starting blank
(2) drawn part
 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
 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
 Reduction r
• Again, defined for cylindrical shape:

Db  D p
r
Db

• Value of r should be less than 0.50

 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
 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
 Other deep-drawing operations:

Redrawing Reverse Drawing

(1) start
(2) finish
Common defects in deep-drawn parts

a) wrinkling in flange
b) wrinkling in walls
c) tearing
d) earing
e) surface scratches
 Other Sheet Metal Forming on
Presses
Other sheet metal forming operations
performed on conventional presses
• Operations performed with metal tooling
• Operations performed with flexible rubber
tooling
 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
Dies for Sheet Metal Processes
Most pressworking operations performed
with conventional punch and die tooling
• Custom designed for particular part
• The term stamping die sometimes used for
high production dies
Components of a punch and die for a blanking operation
 Sheet Metal Operations
Not Performed on Presses

• Roll bending
• Roll forming
• Stretch forming
• Spinning
• High energy rate forming processes.
 Sheet Metal Operations
Not Performed on Presses

• Roll bending
• Roll forming
• Stretch forming
• Spinning
• High energy rate forming processes.
 Roll Bending
Large metal sheets and plates are formed
into curved sections using rolls
 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