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EIN 3390 Chap 17 Sheet-Forming Processes Part 1 Spring 2012
EIN 3390 Chap 17 Sheet-Forming Processes Part 1 Spring 2012
Chapter 17
Sheet Forming Processes
(Part 1)
Shearing & Bending
EIN 3390
Manufacturing Processes
Spring, 2012
17.1 Introduction
Sheet metal processes involve plane
stress loadings and lower forces than
bulk forming
Almost all sheet metal forming is
considered to be secondary processing
The main categories of sheet metal
forming are:
Shearing
Bending
Drawing
Blanking
Piercing
Notching
Trimming
Shearing Operations
Shearing Operations
Shearing Operations
Types of Shearing
Shearing Operations
Figure 17-2 (Left)
(Top) Conventionally
sheared surface
showing the distinct
regions of deformation
and fracture and
(bottom) magnified
view of the sheared
edge. (Courtesy of
Feintool Equipment
Corp., Cincinnati, OH.)
Shearing Operations
Figure 17-4
Fineblanked
surface of the
same
component as
shown in
Figure 17-2.
(Courtesy of
Feintool
Equipment
Corp.,
Cincinnati,
OH.)
Basic components of a
piercing and blanking die
set are: punch, die, and
stripper plate
Punches and dies should
be properly aligned so that
a uniform clearance is
maintained around the
entire border
Punches are normally
made from low-distortion
or air-hardenable tool steel
Blanking Operations
Figure 17-12
Blanking with a
square-faced
punch (left) and
one containing
angular shear
(right). Note the
difference in
maximum force
and contact
stroke. The total
work (the are
under the curve)
is the same for
both processes.
Blanking Operations
Figure 17-13 (Below) Typical die set
having two alignment guideposts.
(Courtesy of Danly IEM, Cleveland,
OH.)
Design rules
Design Clearance
Clearance Calculation
The recommended clearance is:
C = at
Where c clearance, in (mm); a allowance; and t =
stock thickness, in (mm).
Allowance a is determined according to type of metal.
Cutting Forces
Cutting forces are used to determine size of the
press needed.
F = StL
Where S shear strength of the sheet metal, lb/in2 (Mpa); t
sheet thickness in. (mm); and L length of the cut edge,
in. (mm).
In blanking, punching, slotting, and similar operations, L is
the perimeter length of blank or hole being cut.
Note: the equation assumes that the entire cut along
sheared edge length is made at the same time. In this
case, the cutting force is a maximum.
Angular Clearance
for slug or blank to drop through the die, the die opening
must have an angular clearance of 0.25 to 1.50 on each
side.
Design Example
Figure 17-18 Method for making a simple washer in a compound piercing and blanking die.
Part is blanked (a) and subsequently pierced (b) in the same stroke. The blanking punch
contains the die for piercing.
17.3 Bending
Example of Bending
Figure 17-22 Press brake dies can form a variety of angles and contours. (Courtesy of
Cincinnati Incorporated, Cincinnati, OH.)
Bar Folder
Figure 17-20 Phantom section of a bar folder, showing position and operation of
internal components. (Courtesy of Niagara Machine and Tool Works, Buffalo, N.Y.)
Press Brake
Figure 17-21 (Left) Press brake with CNC gauging system. (Courtesy of DiAcro Division,
Acrotech Inc., Lake City, MN.) (Right) Close-up view of press brake dies forming corrugations.
(Courtesy of Cincinnati Incorporated, Cincinnati, OH.)
If the punch
radius is large
and the bend
angle is shallow,
large amounts of
springback are
often
encountered
The sharper the
bend, the more
likely the surfaces
will be stressed
beyond the yield
point
Figure 17-25 Bends should be made with the bend
axis perpendicular to the rolling direction. When
intersecting bends are made, both should be at an
Design Considerations
Figure 17-26 One method of determining the starting blank size (L) for several
bending operations. Due to thinning, the product will lengthen during forming. l1, l2,
and l3 are the desired product dimensions. See table to determine D based on size
of radius R where t is the stock thickness.
Roll Bending
Figure 17-29 (a) Draw bending, in which the form block rotates; (b) compression bending,
in which a moving tool compresses the workpiece against a stationary form; (c) press
bending, where the press ram moves the bending form.
Tube Bending
Roll Forming
Roll forming is a process by which a metal strip is
progressively bent as it passes through a series of
forming rolls
Only bending takes place during this process, and all
bends are parallel to one another
A wide variety of shapes can be produced, but
changeover, setup, and adjustment may take several
hours
Figure 17-31 Eight-roll sequence for the roll forming of a box channel. (Courtesy of the
Aluminum Association, Washington, DC.)
Straightening
Straightening or flattening is the opposite of bending
Done before subsequent forming to ensure the use of
flat or straight material
Various methods to straighten material
SB = (A Ab)/Ab
= 1.33 (65,000)(1.75)(0.125)2/1.0
= 2,364 lb
Homework
Review questions (page 457 - 458):
6, 10, 20, 26
Problems (page 458):
1: a, b