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Manufacturing Technology 2
Week 4
Sheet Metal Forming Processes
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Introduction
1. Sheet metal processes involve plane stress loadings
and lower forces than bulk forming
2. Almost all sheet metal forming is considered to be
secondary processing
3. The main categories of sheet metal forming are
Shearing
Bending
Drawing
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Shearing
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Shearing
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Shearing
As clearance increases, edges rougher and deformation
zone larger. (material tends to be pulled into die rather
than sheared)
Clearances usually range between 2 10 % of sheet
thickness
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Shearing
Punch force
The punch force is product of shear strength of sheet
metal and cross-sectional area being sheared.
Maximum punch force is
Fmax 0.7UTS tL
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Example
Calculation of maximum punch force
Estimate the force required in punching a 25-mm diameter hole through a
1.8-mm-thick 5052-O aluminium sheet at room temperature.
Solution
UTS for this alloy is 190 MPa.
F 0.71.8 25190 18800 N
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Shearing operations
Common shearing operations are:
1. Die cutting
Parts produced have various uses:
a) Perforating
b) Parting
c) Notching
d) Slitting
e) Lancing
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Shearing operations
2. Fine blanking
Can produce very smooth and square edges.
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Shearing operations
3. Slitting.
Carried out with a pair of circular blades.
2 types of slitting equipment:
1. driven type, the blades are powered
2. pull-through type, the strip is pulled through idling
blades.
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Bending
Bending is defined as the straining of the sheet metal
around a straight edge
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1)
Springback
Plastic deformation is followed by some elastic recovery
when load is removed. (called springback)
Final bend angle after spring back is smaller than the
angle to which sheet was bent
Negative springback in V-die
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Forces
Fmax
UTS LT 2
k
W
K ranges from 0.3 / 1.3 depending on die
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Tube bending
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Deep Drawing
Drawing is a sheet-metal operation to make hollow-shaped parts
from a sheet blank
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Deep Drawing
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Deep Drawing
Deep Drawing
Variables in deep drawing are:
1. Properties of the sheet metal.
2. Ratio of the blank diameter to the punch diameter.
3. Sheet thickness.
4. Clearance between the punch and the die.
5. Corner radii of the punch and die.
6. Blankholder force.
7. Speed of the punch.
8. Friction at the punch, die and workpiece interfaces.
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Deep Drawing
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ln
w f
w
Normal anisotropy of the sheet metal is
R
Average R value is
4
where the subscripts refer to angular orientation
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t0
ln
t
f
Earing
In deep drawing, the edges of cups may become wavy
(called earing)
Planar anisotropy causes ears to form in drawn cups.
The controlling parameters:
1. alloying elements
2. processing temperatures
3. annealing cycles after processing
4. thickness reduction in rolling
5. cross (biaxial) rolling of plates to make sheets
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Deep drawability
Maximum punch force
Work consists of deformation, redundant, frictional and
ironing.
Approximate formula for the maximum punch force is
Fmax
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D0
D p T UTS
0.7
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Deep-Drawing practice
Considerations in deep drawing:
1. Clearances and radii
2. Draw beads
3. Blankholder pressure
4. Redrawing
5. Drawing without a blankholder
6. Tooling and equipment
7. Lubrication
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Deep-Drawing practice
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Example
A cup is being drawn from a sheet metal that has a
normal anisotropy of 3.Estimate the maximum ratio of
cup height to cup diameter that can be drawn
successfully in a single draw. Assume that the thickness
of the sheet throughout the cup remains the same as the
original blank thickness and limited drawing ratio of 2.68
Since, volume of the sheet metal in cup is equal to volume of blank
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Example contd.
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Thank you
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