MECH152-L21 (1.

0) - 1
Sheet Metalworking
MECH152-L21 (1.0) - 2
Cutting Operations
Shearing by two sharp cutting edges.
Plastic deformation penetration fracture

MECH152-L21 (1.0) - 3
Shearing, Blanking and Punching
Shearing - Cutting on sheet-metal with
straight edges.
Blanking - Cutting sheet-metal with a closed
contour.
Punching - Making holes on sheet-metal.
MECH152-L21 (1.0) - 4
Sheet-metal Cutting
c = at
c = clearance
a = allowance
t = thickness

Blanking:
Blanking punch dia. = D
b
- 2c
Blanking die dia. = D
b

Punch
Hole punch dia. = D
b
Hole die dia. = D
b
+ 2c



0.25 to 1.5
MECH152-L21 (1.0) - 5
Sheet-metal Cutting
Small clearance
Large clearance
Cutting force = StL
S = Shear strength of sheet-metal
t = Sheet-metal thickness
L = Length of cutting edge
or, Cutting force = 0.7TtL
T = Ultimate tensile strength of sheet-metal
MECH152-L21 (1.0) - 6
Sheet-metal Cutting Operations
Cut-off

Parting
Slotting Perforating Notching / Seminotching
MECH152-L21 (1.0) - 7
Sheet-metal Cutting Operations
Fine blanking -
close tolerances
and smooth
edges in one
step.
Trimming - Cutting operation to remove excess metal
Shaving - Shearing with very small clearance to obtain
accurate dimensions., secondary or finishing operation.
MECH152-L21 (1.0) - 8
Bending
V- bending Edge - bending
MECH152-L21 (1.0) - 9
Bending Analysis
BA = 2 t A( R + K
ba
t ) / 360
where BA = bending allowance, A = bend angle, R = bend
radius, t = stock thickness, K
ba
= stretch factor.
For R< 2t, K
ba
= 0.33 ; for R> 2t, K
ba
= 0.5.

Spring back,

where A = include angle of sheet-metal part
A
b
= include angle of bending tool
w = width of sheet-metal
Bending force D = die opening dimension
K
bf
= 1.33 V-bending


K
bf
= 0.33 edge bending


b
b
A
A A
SB
'
'

'
=
D
Twt K
F
bf
2
=
MECH152-L21 (1.0) - 10
Bending Analysis


Spring back




Die-opening
dimension
MECH152-L21 (1.0) - 11
Bending Operations
Straight flanging Stretch flanging Shrink flanging
Hemming Seaming Curling
MECH152-L21 (1.0) - 12
Bending Operations
Channel bending U-bending air-bending
Offset-bending Corrugating Tube forming
MECH152-L21 (1.0) - 13
Drawing
c = Clearance
D
b
= blank diameter
D
p
= Punch diameter
R
d
= die corner
radius
R
p
= Punch corner
radius
F = drawing force
F
h
= holding force
MECH152-L21 (1.0) - 14
Deep Drawing
Initial step bending of edge straightening of side wall
Thinning and drawing final cup shape
MECH152-L21 (1.0) - 15
Drawing Analysis
Drawing ratio, s 2.0
where D
b
= blank diameter
D
p
= punch diameter
t = thickness of the starting blank
Reduction, s 0.5

Thickness to diameter ratio, > 1%
Drawing force, , max. at 1/3 stroke.

Holding force,
Holding pressure may be set at 0.015 of the yield strength
T = Tensile strength, Y = Yield strength, R
d
= die corner
radius

p
b
D
D
DR =
p
p b
D
D D
r

=
b
D t /
) 7 . 0 ( =
p
b
p
D
D
tT D F t
| |
2 2
) 2 2 . 2 ( 015 . 0
d p h
R t D D Y F
b
+ + = t
MECH152-L21 (1.0) - 16
Drawing Analysis
Blank diameter can be calculated from the conservation of
volume based on the final volume of the part.
If the limits on the drawing ratio, reduction and thickness-
to-diameter ratio are exceeded, the blank must be drawn in
steps or having annealing between the steps.
Process optimization:
Punch and die corner radii
friction
depth of draw (per step)
material characteristics
MECH152-L21 (1.0) - 17
Drawing Defects
a) Wrinkling in flange - small holding force
b) Wrinkling in the wall - insufficient holding force,
wrinkling initially occurring on the flange.
c) Tearing - high stress, sharp die radius
d) Earing - anisotropy of the material
e) Surface scratches - Die or punch not having a smooth
surface, insufficient lubrication

MECH152-L21 (1.0) - 18
Other Sheet-metal Operations
Ironing - squeezing and
drawing in conjunction
Corning & Embossing - to
produce surface details
Lancing - combination of
cutting and forming
MECH152-L21 (1.0) - 19
Other Sheet-metal Operations
Rubber forming processes:
Guerin process - low cost,
small volume, pressure
up 10 MPa.
Hydroforming - Higher
pressure, up to 100 MPa.
MECH152-L21 (1.0) - 20
Dies
Components of a punch and die for blanking operation
MECH152-L21 (1.0) - 21
Dies
Progressive dies
and final part
MECH152-L21 (1.0) - 22
Press



Press are driven mechanically or
hydraulically.

Knuckle joint
crankshaft
eccentric
MECH152-L21 (1.0) - 23
Stretch Forming
Stretching and forming with a die at the same time.
MECH152-L21 (1.0) - 24
Roll Forming
Similar to the
the rolling
process but
working on
sheet-metal or
tubes.
MECH152-L21 (1.0) - 25
Spinning
Conventional
spinning
Shear spinning - thinning
and bending occur at the
same time.
MECH152-L21 (1.0) - 26
Spinning
Tube spinning - similar to shear spinning but working on a
tube.
MECH152-L21 (1.0) - 27
High Energy Forming
Explosive forming
Electrohydraulic forming
Electromagnetic forming

MECH152-L21 (1.0) - 28
Tube Bending
Stretch bending

Drawing bending

Compression bending

R/D s 3.0 with mandrel
R/D s 1.5 without mandrel