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Manufacturing Process 2 (Bending of Sheet Metals)

The document discusses various concepts related to bending of sheet metals including: - The three main types of bending are edge bending using a wiping die, V-bending using a V-shaped punch, and U-bending using a U-shaped punch. - Springback occurs after bending as the elastic stresses in the metal are relaxed, causing the bent metal to return slightly towards its original shape. Springback can be reduced by overbending, stretch forming, bottoming, or ironing the bend. - The bend allowance required to account for stretching during bending can be calculated using the given formula involving bend angle, inside radius, distance from neutral axis to inside surface, thickness, and other parameters.

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45 views27 pages

Manufacturing Process 2 (Bending of Sheet Metals)

The document discusses various concepts related to bending of sheet metals including: - The three main types of bending are edge bending using a wiping die, V-bending using a V-shaped punch, and U-bending using a U-shaped punch. - Springback occurs after bending as the elastic stresses in the metal are relaxed, causing the bent metal to return slightly towards its original shape. Springback can be reduced by overbending, stretch forming, bottoming, or ironing the bend. - The bend allowance required to account for stretching during bending can be calculated using the given formula involving bend angle, inside radius, distance from neutral axis to inside surface, thickness, and other parameters.

Uploaded by

banana
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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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BENDING OF SHEET METALS

• Bending in sheet metal work is defined as the


straining of the metal around a straight axis.
• During the bending operation, the metal on the
inside of the neutral plane is compressed while
the metal on the outside of the neutral plane is
stretched.
• The metal is plastically deformed so that the
bend takes a permanent set upon removal of the
stresses that caused it.
TYPES OF BENDING - EDGE

In edge bending (wiping die) the material is bend at one


edge with the help of a punch. The workpiece is clamped to
the die block by a spring loaded pad.
V-BENDING

V-bending (air bending) uses V shaped punch to press the work metal.
V-Bending is generally used for low production operations. It is often
performed on a press brake and the associated V-dies are relatively
simple and inexpensive.
U BENDING

U-bending uses a U-shaped punch to give


the required shape to the metal.
Schematic illustrations of various bending operations in a press brake .
SPRINGBACK IN BENDING
After a part has been bent, the bending pressure of the tool is released
on metal and the elastic stresses are relaxed. This causes metal
movement resulting in a decrease in a bend angle. Such a metal
movement is termed as spring-back. Springback is the extent to which
metal tends to return to its original shape or position after undergoing
a
Bending or forming operation.
Spring back characteristics

(i) Harder metals cause more degree of back.


(ii) Soft metals cause lesser degrees of spring back.
(iii) A smaller bend radius causes more degrees of
spring back.
(iv) More degrees of bend cause more degrees of
spring back.
(v) Thicker metals cause more degrees of springback.
Methods to Combat Springback
Overbending
The piece is overbent so that when it springs back it will have
the proper angle. Overbending may be cccomplished by setting
the bending punch and die at a smaller angle than required.
Stretch forming
Consists of stretching the blank so that all the metal is past
the elastic limit. The metal is then forced over the punch to
obtain the desired contour.
Bottoming
Bottoming consists of striking the metal
severely at the radius area. This places the
metal under high compressive strains that
set most of the metal past the yield point
and hence the springback is avoided.
IRONING
Springback can be prevented in wiping dies by ironing the
material. To iron the bend effectively, the distance between
the punch and die must be slightly less than the metal
thickness.
Engineering Analysis of Bending
• Bend Allowance - The determination of the length of the
neutral axis before bending to account for stretching of the final bent
section can be estimated as follows:-


B 2 ( r  kt )
360
B = Bend allowance along neutral axis,cm
= Bend angle in degrees
r = inside radius of bend, cm
k = Distance of neutral axis from the inside surface of the bend
t = sheet thickness, mm.
VALUE OF ‘K’ FOR DIFFERENT
TYPES OF MATERIAL
Ex: Calculate the blank length for bending hard aluminium
for the figure below. All bends 2mm inside radius.
The material thickness is 3 mm.
Ex: The part shown is to be made of 3-mm-thick
sheet hard aluminium. Calculate the length of strip.
Bending Force calculations
Force required to perform bending
Depends on:-

1) Geometry of the punch & die and the


strength
2) thickness
3) width of the sheet metal.
Maximum bending force can be estimated by
means of the following equation:-

2
K . l. ut . t
F
w
l  length of bend , mm
 ut  tensile strength of material , MPa
w  width of die  opening , mm
t  blank thickness, mm
FOR WIPING DIE
Ex: A 37.5 mm long, 19 mm wide and 2.5 mm thick
strip is to be bent in a V shaped die. Calculate
the bending force necessary if the steel has 630
MPa tensile strength. Take the die opening as 8
times the thickness.

Ex: A 30 mm long and 19 mm wide steel strip


having a tensile strength of 590 MPa is to be
bent in a V die. Calculate the maximum
thickness can be bent in the die if the maximum
bending force for the machine is 70 N. take die
opening as 16 times the thickness.
Ex: Calculate the blank length to make the part shown in Fig below. Also
determine the bending force required if the tensile strength of material is
350MPa and die radius is 8 mm. The bend length being 120 cm.
SPRINGBACK
3
Ri  Ri  y   Ri  y 
 4    3    1
Rf  Et   Et 
Ri  initial bend radius
R f  final bend radius
E  Young ' s Modulus
 y  Yield strength of material
t  sheet thickness.
Ex: A 2 mm steel sheet is bent to a radius of 27
mm. assuming that its Yields strength is 250
MPa, calculate the radius of the part after it is
bent. Take Young’s Modulus as 180 GPa.

Ex: A 50 mm long and 22 mm wide steel strip with


a tensile strength of 490 MPa is bent in a wiping
die to a radius of 35 mm. calculate the radius of
the part after it is bent. Take Young’s Modulus &
Yield strength as 170 GPa and 340 MPa. The
bending force for the bending operation is
6500N. The die opening can be taken as 8 times
the thickness.
Ex:
A piece of sheet metal is to be bent using a wiping die as shown
in Figure below. The metal has a modulus of elasticity of 200
GPa, a yield strength of 350 MPa and a tensile strength of
500 MPa. What will be the springback radius of curvature and
approximately what punch force will be required if the die &
punch radius radius is 10mm? Take k as 1/3.
Ex: Calculate the developed length of the part shown in figure below .

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