2017im148, PTD Assignment 6 & 7

Department Of Industrial & Manufacturing Engineering
Name:
Zohaib Sarwar
Registration No:
2017-IM-148
Subject:
Production & Tooling Design Lab
Submitted To:
Sir Awais Ahmed
2017im148
Lab Session # 06
Objective:
Design of bending die for particular bending operation
Theory:
Bending:
Bending is a manufacturing process that produces a V-shape, U-shape, or channel shape along a
straight axis in ductile materials, most commonly sheet metal. Commonly used equipment
include box and pan brakes, brake presses, and other specialized machine presses. Typical
products that are made like this are boxes such as electrical enclosures and rectangular ductwork.
Process:
In press brake forming, a work piece is positioned over the die block and the die block presses
the sheet to form a shape. Usually bending has to overcome both tensile stresses and compressive
stresses. When bending is done, the residual stresses cause the material to spring back towards its
original position, so the sheet must be over-bent to achieve the proper bend angle. The amount of
spring back is dependent on the material, and the type of forming. When sheet metal is bent, it
stretches in length. The bend deduction is the amount the sheet metal will stretch when bent as
measured from the outside edges of the bend. The bend radius refers to the inside radius. The
formed bend radius is dependent upon the dies used, the material properties, and the material
thickness.
The U-punch forms a U-shape with a single punch
Bending Die:
The Bend Die is a tool, a mold, which allows tubes to be bent around it and defines the results
shape of the bent tubes.
3D Drawing of Bending Die & Punch:

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Front View:
Top View:
Left Hand Side:

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Working Principle:
In v-bending, a wedge shaped punch forces the metal sheet or strip into a wedge shaped die
cavity. The bend angle may be acute 90°, or obtuse. As the punch descends, the contact forces at
the die corner produce a sufficiently large bending moment at the punch corner to cause the
necessary deformation. To maintain the deformation to be plane strain, the side creep of the part
during its bending is prevented or reduced by incorporating a spring loaded knurled pin in the
die.
Advantages Of Bottoming:
1. More precise bend than air bending
2. Less spring back
3. Less bending force than air bending
Disadvantages Of Bottoming:
1. No U shape bend possible
2. Separate tooling required for separate angles
3. Not suitable for precise parts.
Lab Session # 07
2017im148
Objective:
Design of drawing die for drawing operation
Theory:
Drawing:
Drawing is a metalworking process which uses tensile forces to stretch metal, glass, or plastic.
As the metal is drawn (pulled), it stretches thinner, into a desired shape and thickness. Drawing
is classified in two types: sheet metal drawing and wire, bar, and tube drawing. The specific
definition for sheet metal drawing is that it involves plastic deformation over a curved axis. For
wire, bar, and tube drawing, the starting stock is drawn through a die to reduce its diameter and
increase its length. Drawing is usually done at room temperature, thus classified a cold
working process, however it may be performed at elevated temperatures to hot work large wires,
rods or hollow sections in order to reduce forces.
Drawing differs from rolling in that the pressure of drawing is not transmitted through the
turning action of the mill but instead depends on force applied locally near the area
of compression. This means the amount of possible drawing force is limited by the tensile
strength of the material, a fact that is particularly evident when drawing thin wires.
The starting point of cold drawing is hot-rolled stock of a suitable size.
Drawing Die:
A die used to shape cuplike articles out of sheet metal that is pushed into it by a punch and
prevented from wrinkling by a blank holder which holds the outer edge of the metal firm.
3D Drawing of Drawing Die:
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Front View:
Side View:
Top View:
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Applications:
The easiest example to visualize is a can, formed by having a circular punch push the blank
down into a circular die. Punching through the bottom of the can will turn it into a short tube.
Deep drawn parts don’t have to be circular though. A stainless steel sink could be deep drawn,
and it’s possible to form more complex shapes than that. Generally speaking though, deep drawn
parts should be axisymmetric as this balances out the deformation. It’s also essential that the
material be suitably ductile.
Advantages of Drawing:
1. Speed.
No other process can match the speed of a punch press moving up and down. It’s usually the
most efficient method if you need a large quantity of parts making.
2. Eliminates assembly steps.
Deep drawing produces shapes with closed ends. That avoids the need to cut and weld multiple
pieces.
3. Seamless.
A deep drawn can or tube shape has no joins. That makes deep drawing an ideal process for
anything that needs to be water or gas-tight.
4. High accuracy.
Parts coming off a forming press are extremely repeatable. Assuming the tooling was made
correctly, they’ll also conform very closely to the drawing.
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5. Produces complex geometries.
We’ve talked here about simple shapes like cans and sinks, but deep drawing can create more
complex forms. How about the oil pan for an engine or complex filter housings?
6. Produces very strong parts.
Many metals work-harden as they deform. Essentially, their crystal structure allows a certain
amount of movement but beyond that it becomes locked. Deep drawing subjects metal to a lot of
deformation, so can result in very hard finished parts.
Disadvantages of Drawing:
The tooling is costly and setup can be time-consuming so it’s more suited to high volumes
and long runs.
2017im148

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3D Drawing of Bending Die & Punch:

Left Hand Side:

3D Drawing of Drawing Die:

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