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SMW Lect 1

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14 views30 pages

SMW Lect 1

Uploaded by

e22mecu0009
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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LECTURE 1: SHEET METAL WORKING

What is Sheet Metal Working?

It is defined as cutting and forming operations performed


on relatively thin sheets of metal

1. Thickness of sheet metal = 0.4 mm (1/64 in) to 5


mm (1/4 in)

2. Thickness of plate stock > 5 mm

3. Operations usually performed as cold working


SHEET METALWORKING

1. Cutting Operations
2. Bending Operations
3. Drawing
4. Dies and Presses for Sheet Metal Processes
5. Other Sheet Metal Forming Operations
6. Sheet Metal Operations Not Performed on Presses
7. Bending of Tube Stock
Sheet and Plate Metal Products

Sheet and plate metal parts for consumer and industrial


products include;
▪ Automobiles, Airplanes and trucks
▪ Railway cars and locomotives
▪ Farm and construction equipment
▪ Small and large appliances
▪ Office furniture
▪ Computers and office equipment
Advantages of Sheet Metal Parts

1. High strength
2. Good dimensional accuracy
3. Good surface finish
4. Relatively low cost
5. Economical mass production for large
quantities
Three Major Categories of Sheet Metal Processes

1. Cutting
a) Shearing to separate large sheets
b) Blanking to cut part perimeters out of sheet metal
c) Punching to make holes in sheet metal
2. Bending
a) Straining sheet around a straight axis
3. Drawing
a) Forming of sheet into convex or concave shapes
Sheet Metal Cutting

(1) Just before punch contacts work; (2) punch pushes into work, causing
plastic deformation; (3) punch penetrates into work causing a smooth cut
surface; and (4) fracture is initiated at opposing cutting edges to separate
the sheet
Shearing, Blanking, and Punching

1. Three principal operations in press working that cut


sheet metal are:
a) Shearing
b) Blanking
c) Punching
Shearing Operation

(a) Side view of the operation; (b) front view of power shears
equipped with inclined upper cutting blade
Blanking and Punching

a) Blanking - sheet metal cutting to separate piece (called a


blank) from surrounding stock,
b) Punching - similar to blanking except cut piece is scrap,
called a slug
Punch and Die Sizes

Die size determines blank


size Db
Punch size determines hole
size Dh
c = clearance
Punch and Die Sizes

1) For a round blank of diameter Db:

i. Blanking punch diameter = Db − 2c

ii. Blanking die diameter = Db , where c = clearance

2) For a round hole of diameter Dh:

i. Hole punch diameter = Dh

ii. Hole die diameter = Dh + 2c, where c = clearance


Clearance in Sheet Metal Cutting

Distance between the punch and die


1. Typical values range between 4% and 8% of stock
thickness
a) If too small, fracture lines pass each other, causing
double burnishing and larger force
b) If too large, metal is pinched between cutting
edges and excessive burr results
Cutting Forces

For determining press size (tonnage), punching


force is ;
F = Ys . t . L
where Ys = shear strength of metal;
t = stock thickness, and L = length of cut edge
Stripping Force

 Due to the release of the stored elastic energy in the


stock left on the die, the stock tends to grip the
punch as the punch moves upward.
 This necessitates the use of a stripper to separate the
punch from the stock.
 A general estimate of the stripping force may vary
from 2.5 to 20 % of the punch force but 5 to 10
percent is good for most of the applications.
Numerical

Determine the die and punch sizes for blanking and punching operations for
a circular disc of 20 mm dia from a C20 sheet of thickness 1.5 mm. Given-
s(shear strength) = 294 MPa, C = 0.0032. s. t. Also calculate punching and
stripping forces. [Stripping force = 0.024 Lt]
Sheet Metal Bending

(a) Straining of sheet metal around a straight axis to take a permanent bend,
(b) metal on inside of neutral plane is compressed, metal on outside of
neutral plane is stretched
Types of Sheet Metal Bending

1. V-bending - performed with a V-shaped die


2. Edge bending - performed with a wiping die

(1) Before bending


(2) After bending
a)Low production
b)V-dies are simple
and inexpensive
Edge Bending

(1) Before bending,


(2) After bending

Applications:
1)High production
2) Dies are more
complicated and costly
Spring-back Effect

▪ Increase in included angle of bent part relative to included angle


of forming tool after tool is removed
▪ Reason for spring-back:
When bending pressure is removed, elastic energy remains
in bent part, causing it to recover partially toward its
original shape
Spring-back results in a
decrease in bend angle and an
increase in bend radius:
(1) during bending, work is
forced to take radius Rt and
angle b' of the bending tool,
(2) after punch is removed,
work springs back to R and '
The magnitude of spring back will vary according to material
type, thickness, and hardness. A larger bend radius will also
cause greater spring back.
• Spring back for low-carbon and soft nonferrous material is
from 0 to 2°
• For carbon steel spring back may vary from 3 to 5 °
• Spring back may be as high as 10 to 15° in harder materials.
Bending Allowance

When a blank or sheet is to be bent, it is necessary to consider the


effect of stretching the metal at the outside of the bend. Since there
is no stretch in the neutral plane, the length of the formed part along
the neutral plane will be the correct length. The curved neutral plane
of the bend area is called the bend allowance
Stretching during Bending

1. If bend radius is small relative to stock thickness, metal tends to


stretch during bending
2. Need to estimate amount of stretching, so final part length =
specified dimension
3. Problem is to determine the length of neutral axis of the part
before bending to account for stretching. This length is called
bend allowance, and is given as;
α
Ab = 2π ( R + K bat )
360
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
Bending Force

Maximum bending force estimated as follows:


𝐾𝑏𝑓 𝑇𝑤𝑡 2
𝐹=
𝐷

where F = bending force; T = tensile strength of sheet metal; w


= width of part in the direction of bent axis; and t = stock
thickness. D = die opening dimension, 𝐾𝑏𝑓 factor accounts for
type of bending; V bending or edge bending operation.

For V-bending, Kbf = 1.33;


For edge bending, Kbf = 0.33
Die Opening Dimension

Die opening dimension D for (a) V-die, (b) wiping die


Numerical
Also calculate the stripping force

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