Casting
Forming
Sheet metal processing
Powder- and Ceramics Processing
Plastics processing
Cutting
Joining
Surface treatment
Processes:
Shearing
Punching
Bending
Deep drawing
Hydroforming
Shearing
Main use: to cut large sheet into smaller sizes for making parts.
Shearing
Shearing is a process for cutting sheet metal to size out of a
larger stock such as roll stock. Shears are used as the
preliminary step in preparing stock for stamping processes.
Material thickness ranges from 0.125 mm to 6.35 mm
(0.005 to 0.250 in). The dimensional tolerance ranges from
0.125 mm to 1.5 mm (0.005 to 0.060 in).
The shearing process produces a shear edge burr, which
can be minimized to less than 10% of the material
thickness. The burr is a function of clearance between the
punch and the die (which is nominally designed to be the
material thickness), and the sharpness of the punch and
the die.
Blanking / Punching
Blanking and punching are similar sheet metal
cutting operations that involve cutting the
sheet metal along a closed outline.
If the part that is cut out is the desired
product, the operation is called blanking
and the product is called blank. If the remaining
stock is the desired part, the operation is called
punching.
Blanking / Punching
crack
(failure in shear)
Punch
sheet
die
die
clearance
Punching
nesting of parts
Bending
(a)
(b)
Bending mechanics
This section is
under extension
T = Sheet thickness
Neutral axis
L = Bend length
This section is
in compression
R = Bend radius
Poisson effect
Bending: springback
T
Final
R
Rf
Initial
i
f
R
RY
RY
(a) Compensation: the metal is bent by a larger angle i 4 i 3 i 1
Rf
ET
ET
Deep Drawing
blank holder
blank
punch
punch
punch
part
die
die
(a)
die
die
(b)
(c)
die
(d)
(e)