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sheet metal
1.
SHEET METALWORKING
1. Cutting Operations 2. Bending Operations 3. Drawing 4. Other Sheet Metal Forming Operations 5. Dies and Presses for Sheet Metal Processes 6. Sheet Metal Operations Not Performed on Presses 7. Bending of Tube Stock ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
2.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
3.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
4.
Advantages of Sheet
Metal Parts High strength Good dimensional accuracy Good surface finish Relatively low cost Economical mass production for large quantities ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
5.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
6.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
7.
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; ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
8.
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. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
9.
Shearing, Blanking, and
Punching Three principal operations in pressworking that cut sheet metal: Shearing Blanking Punching ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
10.
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. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
11.
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. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
12.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
13.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
14.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
15.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
16.
Punch and Die
Sizes Figure 20.6 Die size determines blank size Db; punch size determines hole size Dh.; c = clearance ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
17.
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. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
18.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
19.
Sheet Metal Bending
Straining sheetmetal around a straight axis to take a permanent bend Figure 20.11 (a) Bending of sheet metal ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
20.
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. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
21.
Types of Sheet
Metal Bending V‑bending - performed with a V‑shaped die Edge bending - performed with a wiping die ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
22.
V-Bending
For low production Performed on a press brake V-dies are simple and inexpensive Figure 20.12 (a) V‑bending; ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
23.
Edge Bending
For high production Pressure pad required Dies are more complicated and costly Figure 20.12 (b) edge bending. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
24.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
25.
Bend Allowance Formula
α Ab = 2π ( R + K ba t ) 360 where Ab = bend allowance; α = 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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
26.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
27.
Springback
α α 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 αb' of the bending tool, (2) after punch is removed, the work springs back to radius R and angle α‘. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
28.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
29.
Die Opening Dimension Figure
20.14 Die opening dimension D: (a) V‑die, (b) wiping die. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
30.
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) ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
31.
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. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
32.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
33.
Tests of Drawing
Feasibility Drawing ratio Reduction Thickness-to-diameter ratio ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
34.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
35.
Reduction r
Defined for cylindrical shape: Db − Dp r= Db Value of r should be less than 0.50 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
36.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
37.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
38.
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 ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
39.
Other Sheet Metal
Forming on Presses Other sheet metal forming operations performed on conventional presses Operations performed with metal tooling Operations performed with flexible rubber tooling ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
40.
Ironing
Makes wall thickness of cylindrical cup more uniform Figure 20.25 Ironing to achieve more uniform wall thickness in a drawn cup: (1) start of process; (2) during process. Note thinning and elongation of walls. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
41.
Embossing
Creates indentations in sheet, such as raised (or indented) lettering or strengthening ribs Figure 20.26 Embossing: (a) cross‑section of punch and die configuration during pressing; (b) finished part with embossed ribs. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
42.
Guerin Process Figure 20.28
Guerin process: (1) before and (2) after. Symbols v and F indicate motion and applied force respectively. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
43.
Advantages of Guerin
Process Low tooling cost Form block can be made of wood, plastic, or other materials that are easy to shape Rubber pad can be used with different form blocks Process attractive in small quantity production ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
44.
Dies for Sheet
Metal Processes Most pressworking operations performed with conventional punch‑and‑die tooling Custom‑designed for particular part The term stamping die sometimes used for high production dies ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
45.
Punch and Die
Components Figure 20.30 Components of a punch and die for a blanking operation. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
46.
Progressive Die Figure 20.31
(a) Progressive die; (b) associated strip development ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
47.
Stamping Press Figure 20.32
Components of a typical mechanical drive stamping press ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
48.
Types of Stamping
Press Frame Gap frame Configuration of the letter C and often referred to as a C‑frame Straight‑sided frame Box-like construction for higher tonnage ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
49.
Figure 20.33 Gap
frame press for sheet metalworking (ohoto courtesy of E. W. Bliss Co.); capacity = 1350 kN (150 tons) ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
50.
Figure 20.34 Press brake
(photo courtesy of Niagara Machine & Tool Works); bed width = 9.15 m (30 ft) and capacity = 11,200 kN (1250 tons). ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
51.
Figure 20.35 Sheet
metal parts produced on a turret press, showing variety of hole shapes possible (photo courtesy of Strippet Inc.). ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
52.
Figure 20.36 Computer
numerical control turret press (photo courtesy of Strippet, Inc.). ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
53.
Figure 20.37 Straight‑sided frame press
(photo courtesy of Greenerd Press & Machine Company, Inc.). ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
54.
Power and Drive
Systems Hydraulic presses - use a large piston and cylinder to drive the ram Longer ram stroke than mechanical types Suited to deep drawing Slower than mechanical drives Mechanical presses – convert rotation of motor to linear motion of ram High forces at bottom of stroke Suited to blanking and punching ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
55.
Operations Not Performed
on Presses Stretch forming Roll bending and forming Spinning High‑energy‑rate forming processes. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
56.
Stretch Forming
Sheet metal is stretched and simultaneously bent to achieve shape change Figure 20.39 Stretch forming: (1) start of process; (2) form die is pressed into the work with force Fdie, causing it to be stretched and bent over the form. F = stretching force. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
57.
Force Required in
Stretch Forming F = LtYf where F = stretching force; L = length of sheet in direction perpendicular to stretching; t = instantaneous stock thickness; and Yf = flow stress of work metal Die force Fdie can be determined by balancing vertical force components ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
58.
Roll Bending
Large metal sheets and plates are formed into curved sections using rolls Figure 20.40 Roll bending. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
59.
Roll Forming
Continuous bending process in which opposing rolls produce long sections of formed shapes from coil or strip stock Figure 20.41 Roll forming of a continuous channel section: (1) straight rolls, (2) partial form, (3) final form. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
60.
Spinning
Metal forming process in which an axially symmetric part is gradually shaped over a rotating mandrel using a rounded tool or roller Three types: 1. Conventional spinning 2. Shear spinning 3. Tube spinning ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
61.
Conventional Spinning Figure 20.42
Conventional spinning: (1) setup at start of process; (2) during spinning; and (3) completion of process. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
62.
High‑Energy‑Rate Forming (HERF)
Processes to form metals using large amounts of energy over a very short time HERF processes include: Explosive forming Electrohydraulic forming Electromagnetic forming ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
63.
Explosive Forming
Use of explosive charge to form sheet (or plate) metal into a die cavity Explosive charge causes a shock wave whose energy is transmitted to force part into cavity Applications: large parts, typical of aerospace industry ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
64.
Explosive Forming Figure 20.45
Explosive forming: (1) setup, (2) explosive is detonated, and (3) shock wave forms part and plume escapes water surface. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
65.
Electromagnetic Forming
Sheet metal is deformed by mechanical force of an electromagnetic field induced in the workpart by an energized coil Presently the most widely used HERF process Applications: tubular parts ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
66.
Electromagnetic Forming Figure 20.47
Electromagnetic forming: (1) setup in which coil is inserted into tubular workpart surrounded by die; (2) formed part. ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
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