ME477 Fall 2004

Introduction
SHEET • Cutting and forming thin sheets of metal usually
METALWORKING performed as cold working
• Sheet metal = 0.4 (1/64) to 6 mm (1/4in) thick
1. Cutting Operation • Plate stock > 6 mm thick
2. Bending Operation • Advantage - High strength, good dimensional
3. Drawing accuracy, good surface finish, economical mass
4. Other Sheet-metal Forming production (low cost).
5. Dies and Presses • Cutting, bending, drawing
γ
6. Sheet-metal Operation ε1 Localized necking
7. Bending of Tube Stock θ=55° Because ν=0.5 in plasticity, ε
ε2 ε1=-2ε2=-2ε3 ε3,ε2 2θ ε1
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Sheet Metalworking Terminology Sheet-metal Characteristics

• Elongation – the capability of the sheet metal to
stretch without necking and failure.
• “Punch-and-die” • Yield-point elongation
– Tooling to perform cutting, bending, and – Lüeder’s bands on Low-carbon steels and Al-Mg alloys.
Lüder’s bands can be eliminated by cold-rolling the
drawing thickness by 0.5-1.5%.
Yupper
• “Stamping press” Ylower

– Machine tool that performs most sheet metal • Anisotropy

operations – Crystallographic and mechanical fibering anisotropy
• Grain Size effect on mechanical properties
• “Stampings” • Residual Stress, Springback and Wrinkling
– Sheet metal products • Testing method
– Cupping test
– Forming Limit Diagram
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1. Cutting Operation Cutting Operation

• Cutting operation
– Plastic deformation Punch
– Penetration (1/3 thickness)
t
– Fracture
Die
• Shearing using a machine called power
shear or square shear.
c
• Blanking – shearing a closed outline Rollover
(desired part called blank) part
Burnish
• Punching – sheared part is slag (or scrap)
Fracture zone
and remaining stock is a desired part
Burr
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part

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Analysis Die, blank and punch size

• Clearance - 4-8% but sometime 1% of thickness For a round blank,
– Too small – fracture does not occur requiring more force. Blank punch diameter=Db-2c
Blank die diameter = Db
– Too large – Get pinched and cause an excessive burr
For a round hole,
• Clearance: c=a*t
Dh Hole punch diameter=Dh
– Metal group a c c Hole die diameter = Dh+2c
– 1100S and 5052S aluminum alloys, all tempers 0.045 Db Angular clearance of 0.25o to 1.5o
– 2024ST and 6061ST aluminum alloys;
brass, soft cold rolled steel, soft stainless steel 0.060 Cutting forces: F=S*t*L=0.7*TS*t*L
– Cold rolled steel, half hard; stainless steel, where S= Shear strength
half hard and full hard 0.075 t=thickness
L=length of cutting edge
Angular clearance TS =Ultimate tensile strength
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Other Cutting Operations 2. Bending Operations

part

• Cutoff and Parting part

part

scrap
• V-bending
• Slotting, Perforating and Notching

• Trimming, Shaving and Fine Blanking • Edge Bending

Trimming
Shaving Fine Blanking 9 10

Analysis of Bending I Analysis of Bending II

• Bend Allowance - length of a neutral axis • Compensate for spring back
BA = 2π
A
(R + K ba t ) – Overbending
360
A = Bend Angle – Bottoming – squeezing the part at the end of
R = Bend Radius
A’
the stroke K bf (TS )wt 2
A t = Stock Thickness
• Bending force: F = D
K ba = A Factor to Estimate Stretch w
Kba=0.33 if R<2t and Kba=0.5 if R≥2t
– Kbf=1.33 for V-bending
A' − Ab' – Kbf=0.33 for Edge-bending
• Springback SB =
Ab' – w= width of part D

A' = included angle of the sheet metal part – t=stock thickness

Ab' = included angle of the bending tool – D=die opening dimension D
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Other Bending Operation 3. Drawing

• Flanging • Basic drawing operation – a cup-shape
• Hemming part
F
• Seaming
Fh Fh
• Curling Dp
• Channel,
• U-bending
Air bending, c c Dp
Offset bending,
Corrugating and Db
Tube forming 13 14

Detail Steps of Drawing Analysis of Drawing

v v
Fv Fv Fv Fv • Measure of Drawing
D
– Drawing ratio: DR = b feasible if DR<2
D
D − Dp p
Fv
v
Fv – Reduction: r = b feasible if r<0.5
Db
1. Initial Contact 2. Bending – Crude measures of the severity of a deep
Fv v Fv drawing operation ⎛ Db ⎞
• Drawing Forces: F = πD pt (TS )⎜⎜ − 0.7 ⎟⎟
Fv v Fv
3. Straightening
⎝ Dp ⎠
Max at 1/3 length
• Holding Force: Fh = 0.015Yπ [Db2 − (D p + 2.2t + 2 Rd ) ]
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4. Friction & 5. Final Shape

Compression 15 16

Other Drawing Operation Forming-Limit Diagram

• A grid pattern of circles, typically 2.5 to 5mm in diameter,
• Redrawing produced by electrochemical or photoprinting.
• After drawing, the circles are observed for failure.
• Drawing without a Blankholder
• The major strain is on the major direction and magnitude
• Not cylindrical cups of strain
• Defects (Fig. 20.24)
– Wrinkling in the flange 120
Failure
Major strain

– Wrinkling in the wall

Major Axis Major Axis Low Carbon Steel
– Tearing 80
High Strength Steel
Simple
– Earing – anistropy in sheet metal Minor Axis Minor Axis 60 Tension Al alloy
– Surface scratch Pure Equal
shear Safe biaxial

0 0 80
17 -60 Minor strain 18

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4. Other Sheet-Metal Operations 5. Dies and Presses

• Stamping Die
• With Metal Tooling
– Punch
– Ironing – Die Punch Holder
– Coining and Embossing – Stripper
Punch Stripper
– Lancing • Types
– Simple Strip stock

– Compound Guide pin die

• Using hydrostatic pressure – Progressive
– Guerin Process – Rubber pad • Press Die holder

– Hydroforming - Hydraulic fluid – Hydraulic Press base

Blank
– Mechanical
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6. Other Types Sheet Metal Stretch forming and Roll bending &
Operations Forming
• Stretch Forming
• Roll Bending and Forming
• Spinning– make cone, hemisphere, tubes
– Conventional
– Shear
– Tube
• High-Energy-Rate Forming
+
– Explosive Forming
– Electrohydraulic forming + +
– Electromagnetic forming
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Spinning & Explosive forming 7. Bending of Tube Stock

• Bending without collapse and fold
Mandrel

Mandrel

• To avoid flattening
Clamp
Clamp – R(bend radius) > 1.5D(tube diameter) with a mandrel
Roller tool Shear Spinning
– R>3D without mandrel.

Conventional Spinning F • Types

– Stretch bending
Explosive – Draw bending (rotating form)
– Compression bending (form block)
– Roll bending (similar to sheet metal)

Explosive forming Tube Spinning 23 24

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