Chapter 4-2 Sheet Metal Forming

3/25/2015
SHEET METALWORKING
1. Cutting Operations
2. Bending Operations
3. Drawing
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Sheet Metalworking Defined

Cutting and forming operations performed on
relatively thin sheets of metal
Thickness of sheet metal = 0.4 mm (1/64 in) to
6 mm (1/4 in)
Thickness of plate stock > 6 mm
Operations usually performed as cold working
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Sheet and Plate Metal Products

Sheet and plate metal parts for consumer and
industrial products such as
Automobiles and trucks
Airplanes
Railway cars and locomotives
Farm and construction equipment
Small and large appliances
Office furniture
Computers and office equipment
Advantages of Sheet Metal Parts

High strength
Good dimensional accuracy
Good surface finish
Relatively low cost
Economical mass production for large
quantities
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Sheet Metalworking Terminology

Punch-and-die - tooling to perform
cutting, bending, and drawing
Stamping press - machine tool that
performs most sheet metal operations
Stampings - sheet metal products
Basic Types of Sheet Metal Processes

1. Cutting
Shearing to separate large sheets
Blanking to cut part perimeters out of
sheet metal
Punching to make holes in sheet metal
2. Bending
Straining sheet around a straight axis
3. Drawing
Forming of sheet into convex or concave
shapes
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Sheet Metal Cutting
Figure 20.1 Shearing of sheet metal between two cutting edges:

(1) just before the punch contacts work; (2) punch begins to
push into work, causing plastic deformation;
Sheet Metal Cutting
Figure 20.1 Shearing of sheet metal between two cutting edges:

(3) punch compresses and penetrates into work causing a
smooth cut surface; (4) fracture is initiated at the opposing
cutting edges which separates the sheet.
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Shearing, Blanking, and Punching

Three principal operations in pressworking that
cut sheet metal:
Shearing
Blanking
Punching
Shearing
Sheet metal cutting operation along a straight line
between two cutting edges
Typically used to cut large sheets
Figure 20.3 Shearing operation: (a) side view of the

shearing operation; (b) front view of power shears
equipped with inclined upper cutting blade.
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Blanking and Punching

Blanking - sheet metal cutting to separate piece
(called a blank) from surrounding stock
Punching - similar to blanking except cut piece is
scrap, called a slug
Figure 20.4 (a) Blanking and (b) punching.

Clearance in Sheet Metal Cutting

Distance between punch cutting edge and die
cutting edge
Typical values range between 4% and 8% of
stock thickness
If too small, fracture lines pass each other,
causing double burnishing and larger force
If too large, metal is pinched between
cutting edges and excessive burr results
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Clearance in Sheet Metal Cutting

Recommended clearance is calculated by:
c = at
where c = clearance; a = allowance; and t =
stock thickness
Allowance a is determined according to type of
metal
Sheet Metal Groups Allowances
Metal group a
1100S and 5052S aluminum alloys, all 0.045
tempers
2024ST and 6061ST aluminum alloys; 0.060
brass, soft cold rolled steel, soft
stainless steel
Cold rolled steel, half hard; stainless 0.075

steel, half hard and full hard
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Punch and Die Sizes

For a round blank of diameter Db:
Blanking punch diameter = Db - 2c
Blanking die diameter = Db
where c = clearance
For a round hole of diameter Dh:
Hole punch diameter = Dh
Hole die diameter = Dh + 2c
where c = clearance
Punch and Die Sizes
Figure 20.6 Die size

determines blank
size Db; punch size
determines hole
size Dh.; c =
clearance
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Angular Clearance
Purpose: allows slug or blank to drop through die
Typical values: 0.25 to 1.5 on each side
Figure 20.7
Angular
clearance.
Cutting Forces
Important for determining press size (tonnage)
F=StL
where S = shear strength of metal; t = stock
thickness, and L = length of cut edge
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Sheet Metal Bending

Straining sheetmetal around a straight axis to
take a permanent bend
Figure 20.11 (a) Bending of sheet metal
Sheet Metal Bending

Metal on inside of neutral plane is compressed,
while metal on outside of neutral plane is
stretched
Figure 20.11 (b) both

compression and
tensile elongation of the
metal occur in bending.
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Types of Sheet Metal Bending

V-bending - performed with a V-shaped die
Edge bending - performed with a wiping die
V-Bending
For low production
Performed on a press brake
V-dies are simple and inexpensive
Figure 20.12
(a) V-bending;
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Edge Bending
For high production

Pressure pad required
Dies are more complicated and costly
Figure 20.12
(b) edge
bending.
Stretching during Bending

If bend radius is small relative to stock
thickness, metal tends to stretch during
bending
Important to estimate amount of stretching, so
final part length = specified dimension
Problem: to determine the length of neutral axis
of the part before bending
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Bend Allowance Formula

Ab = 2 ( R + K b at )
360
where Ab = bend allowance; = bend angle; R=

bend radius; t = stock thickness; and Kba is
factor to estimate stretching
If R < 2t, Kba = 0.33
If R 2t, Kba = 0.50
Springback
Increase in included angle of bent part relative to
included angle of forming tool after tool is
removed
Reason for springback:
When bending pressure is removed, elastic
energy remains in bent part, causing it to
recover partially toward its original shape
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Springback
Figure 20.13 Springback in bending is seen as a decrease in bend angle

and an increase in bend radius: (1) during bending, the work is forced
to take radius Rb and included angle b' of the bending tool, (2) after
punch is removed, the work springs back to radius R and angle .
Bending Force
Maximum bending force estimated as follows:
K bf TSwt 2
F
D
where F = bending force; TS = tensile

strength of sheet metal; w = part width in
direction of bend axis; and t = stock
thickness. For V- bending, Kbf = 1.33; for
edge bending, Kbf = 0.33
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Die Opening Dimension
Figure 20.14 Die opening dimension D: (a) V-die, (b) wiping die.
Drawing
Sheet metal forming to make cup-shaped,
box-shaped, or other complex-curved,
hollow-shaped parts
Sheet metal blank is positioned over die cavity
and then punch pushes metal into opening
Products: beverage cans, ammunition shells,
automobile body panels
Also known as deep drawing (to distinguish it
from wire and bar drawing)
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Drawing
Figure 20.19 (a) Drawing

of cup-shaped part:
(1) before punch
contacts work, (2)
near end of stroke;
(b) workpart: (1)
starting blank, (2)
drawn part.
Clearance in Drawing
Sides of punch and die separated by a
clearance c given by:
c = 1.1 t
where t = stock thickness
In other words, clearance is about 10% greater
than stock thickness
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Tests of Drawing Feasibility

Drawing ratio
Reduction
Thickness-to-diameter ratio
Drawing Ratio DR
Most easily defined for cylindrical shape:
Db
DR
Dp
where Db = blank diameter; and Dp = punch

diameter
Indicates severity of a given drawing operation
Upper limit: DR 2.0
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Reduction r
Defined for cylindrical shape:

Db Dp
r
Db
Value of r should be less than 0.50
Thickness-to-Diameter Ratio t/Db

Thickness of starting blank divided by blank
diameter
Desirable for t/Db ratio to be greater than 1%
As t/Db decreases, tendency for wrinkling
increases
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Blank Size Determination

For final dimensions of drawn shape to be
correct, starting blank diameter Db must be
right
Solve for Db by setting starting sheet metal
blank volume = final product volume
To facilitate calculation, assume negligible
thinning of part wall
Shapes other than Cylindrical Cups

Square or rectangular boxes (as in sinks),
Stepped cups
Cones
Cups with spherical rather than flat bases
Irregular curved forms (as in automobile body
panels)
Each of these shapes presents its own unique

technical problems in drawing
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3/25/2015

Sheet Metalworking Defined

Sheet and Plate Metal Products

Advantages of Sheet Metal Parts

Sheet Metalworking Terminology

Basic Types of Sheet Metal Processes

Sheet Metal Cutting

Figure 20.1 Shearing of sheet metal between two cutting edges:

Sheet Metal Cutting

Figure 20.1 Shearing of sheet metal between two cutting edges:

Shearing, Blanking, and Punching

Figure 20.3 Shearing operation: (a) side view of the

Blanking and Punching

Figure 20.4 (a) Blanking and (b) punching.

Clearance in Sheet Metal Cutting

Clearance in Sheet Metal Cutting

Sheet Metal Groups Allowances

Cold rolled steel, half hard; stainless 0.075

Punch and Die Sizes

Punch and Die Sizes

Figure 20.6 Die size

Sheet Metal Bending

Figure 20.11 (a) Bending of sheet metal

Sheet Metal Bending

Figure 20.11 (b) both

Types of Sheet Metal Bending

For high production

Stretching during Bending

Bend Allowance Formula

where Ab = bend allowance; = bend angle; R=

Figure 20.13 Springback in bending is seen as a decrease in bend angle

where F = bending force; TS = tensile

Die Opening Dimension

Figure 20.19 (a) Drawing

Tests of Drawing Feasibility

Most easily defined for cylindrical shape:

where Db = blank diameter; and Dp = punch

Defined for cylindrical shape:

Value of r should be less than 0.50

Thickness-to-Diameter Ratio t/Db

Blank Size Determination

Shapes other than Cylindrical Cups

Each of these shapes presents its own unique

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