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. = Db- 2c
Blanking die dia. = Db

0.25 to 1.5

Punch
Hole punch dia. = Db
Hole die dia. = Db+ 2c

MECH152-L21 (1.0) - 5

Sheet-metal Cutting

Small 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

Large clearance

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 A( R + Kbat ) / 360
where BA = bending allowance, A = bend angle, R = bend radius, t =
stock thickness, Kba = stretch factor.
For R< 2t, Kba= 0.33 ; for R 2t, Kba= 0.5.
Spring back,

A Ab
SB
where A = include angle A
ofb sheet-metal part
Ab = include angle of bending tool
w = width of sheet-metal
Bending force
D = die opening dimension
Kbf = 1.33 V-bending
K bf Twt 2

bending
Kbf = 0.33 Fedge
D

MECH152-L21 (1.0) - 10

Bending Analysis
Spring back

Die-opening
dimension

MECH152-L21 (1.0) - 11

Bending Operations

Straight flanging

Hemming

Stretch flanging

Seaming

Shrink flanging

Curling

MECH152-L21 (1.0) - 12

Bending Operations

Channel bending

Offset-bending

U-bending

Corrugating

air-bending

Tube forming

MECH152-L21 (1.0) - 13

Drawing
c = Clearance
Db = blank diameter
Dp = Punch diameter
Rd = die corner
radius
Rp = Punch corner
radius
F = drawing force
Fh = holding force

MECH152-L21 (1.0) - 14

Deep Drawing

Initial step

bending of edge

Thinning and drawing

straightening of side wall

final cup shape

MECH152-L21 (1.0) - 15

Drawing Analysis
Db
Drawing ratio, DR
2.0
Dp

where Db = blank diameter

Dp = punch diameter
t = thickness of the starting blank
Db D p
Reduction, r D
0.5
p

Thickness to diameter ratio, t / Db 1%

Db
F

D
tT
(
0.7), max. at 1/3 stroke.
p
Drawing force,
D
p

2
2
F

0
.
015
Y

(
D

2
.
2
t

2
R
)
p
d
b
Holding force, h

Holding pressure may be set at 0.015 of the yield strength

T = Tensile strength, Y = Yield strength, Rd = die corner radius

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 thicknessto-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
crankshaft

Knuckle joint

eccentric

Press are driven mechanically or

hydraulically.

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 3.0 with mandrel
R/D 1.5 without mandrel