CHAPTER 2 Press Working

Sheet Metal Forming
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CO
 Identify and select proper manufacturing
process for a specific component.
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SHEET METAL WORKING
1. Cutting Operations
2. Bending Operations
3. Drawing
4. Other Sheet Metal Forming Operations
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Sheet Metalworking Defined
Cutting and forming operations performed on relatively
thin sheets of metal
 Thickness of sheet metal = 0.4 mm (1/64in) to 6mm
(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
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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 made by
press machine
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Basic Types of Sheet Metal Processes
1. Cutting
 Shearing to separate large sheets
 Blanking to cut part perimeters out of
sheet metal
 Punching/ Piercing 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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Shearing, Blanking, and Punching
Three principal operations in press working that
cut sheet metal:
 Shearing
 Blanking
 Punching
 Piercing
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Sheet Metal Cutting - Shearing
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;
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Sheet Metal Cutting - Shearing
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
Sheet metal cutting operation along a straight line
between two cutting edges
 Typically used to cut large sheets
Engagement of entire blade

into cutting need higher
forces. Therefore, inclined
blade is used to reduce force
and to improve cut- edge.
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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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, or smaller blanks for
CNC presses
 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, and the sharpness of the punch and the
die.
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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
(a) Blanking and (b) punching.

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Punching and Piercing
0
….
…….. Piercing tool
Punching tool
Bur
Punching Piercing
Slug is cut and bur No slug is cut, only

is minimum bur
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Punching
 Punching is a metal fabricating process that
removes a scrap slug from the metal workpiece
each time a punch enters the punching die. This
process leaves a hole in the metal workpiece
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Punching: operation
 1. Punch, made of hardened steel, is forced through a work-piece.
 2. The punch cuts the metal and separates it in the form of scrap
3. The hole size depends on the punch size
Characteristics:
 Ability to produce economical holes in both strip and sheet metal during
medium or high production processes.
 The ability to produce holes of varying shapes - quickly
Punching is an
operation of cutting
holes into a sheet blank
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Punch Tools
TiN coated tool steel punches
To reduce punch wear

To increase punch life
To increase dimensional accuracy of holes
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Other shearing processes
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Close tolerances and low v
Angular Clearance
Purpose: allows slug or blank to drop through die
 Typical values: 0.25 to 1.5 on each side
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Types of Sheet Metal Bending
 V-bending - performed with a V-shaped die
 Edge bending - performed with a wiping die
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V-Bending
 For low production
 Performed on a brake press
 V-dies are simple and inexpensive
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Edge Bending
 For high production

 Pressure pad required
 Dies are more complicated and costly
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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 that final part length can be
obtained as specified dimension
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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
Difference between
wire drawing &
deep drawing?
(a) Drawing of
cup-shaped part: (1)
before punch
contacts work, (2)
near end of stroke;
(b) work-part: (1)
starting blank, (2)
drawn part.
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Mechanics of Drawing
Straightening the
Bending at
bent sheet,
die and
stretching
Fh: Holding force punch
F: Punch force radius
Wall thickness
variation: yes
Wall thinning
maximum at
bottom corner of
cup (max: 25%)
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Sheet Metal Forming

Visit for more Learning Resources 1

Shearing of sheet metal between two cutting edges: (3) punch

Engagement of entire blade

Shearing operation: (a) side view of the shearing operation;

 Shears are used as the preliminary step in preparing

 The shearing process produces a shear edge burr,

(a) Blanking and (b) punching.

Slug is cut and bur No slug is cut, only

To reduce punch wear

 For high production

 If bend radius is small relative to stock

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