By: Engr. Shamraiz MT-284 MANUFACTURING PROCESSES INSTRUCTOR: SHAMRAIZ AHMAD MS-Design and Manufacturing Engineering [email protected] Topic: Sheet.

By: Engr. Shamraiz

MT-284MANUFACTURING PROCESSES

INSTRUCTOR: SHAMRAIZ AHMAD

MS-Design and Manufacturing Engineering

[email protected]

Topic:Sheet Metal Working (Part-2)

By: Engr. Shamraiz

Straining sheetmetal around a straight axis to take a permanent bend

Figure 20.11 (a) Bending of sheet metal

Sheet Metal Bending (Last Lecture)

By: Engr. Shamraiz

This Lecture• Sheet metal work – Bending (Forming)

– Engineering Analysis of Bending – Other Forms of Bending

• Sheet metal work – Drawing (Forming)– Introduction to drawing operation – Engineering Analysis of drawing – Other Forms of drawing – Defects in drawing

• Some other Sheet metal forminng operations

By: Engr. Shamraiz

Engineering Analysis of Bending• Bending radius R is normally specified on the inside of the part, rather than at the

neutral axis. The bending radius is determined by the radius on the tooling used for bending.

• Bending Allowance: If the bend radius is small relative to sheet thickness, the metal tends to stretch during bending. Knowledge about Stretching is important to have final part length according to specified dimensions.

• It is about determining the length of neutral axis before bending, in accordance with final bend length. The bend allowance (BA) is the length of the arc of the neutral line between the tangent points of a bend in any material. – BA = 2pA(R + Kbat)/360– Where BA – bend allowance(mm); – A - bend angle, degrees; – R – bend radius, in. (mm); – t – sheet thickness; and – Kba - factor to estimate stretching. if R < 2t, Kba = 0.33; and if R>=2t, Kba =0.5.

By: Engr. Shamraiz

Engineering Analysis of BendingSpring back: When the bending pressure is removed at the end of

deformation, elastic energy remains in the bend part, causing it to recover partially toward its original shape.

SB = (A’ – Ab’)/Ab’Where SB – springback; A’ – included angle of sheet-metal part; and Ab’ –

included angle of bending tool, degrees.

By: Engr. Shamraiz

Bending Force: The force required to perform bending depends on the geometry

of the punch and die and the strength, thickness, and width of the sheet metal. The maximum bending force can be estimated by means of the following equation based on bending of a simple beam:

F = (KbfTSwt2)/D

Where F – bending force, lb (N),; TS – tensile strength of the sheet metal, lb/in2. (Mpa); t – sheet thickness, in. (mm); w- width of sheet metal and D – die opening dimension. Kbf – a constant that counts for differences in an actual bending processes. For V-bending Kbf =1.33, and for edge bending Kbf =0.33

Engineering Analysis of Bending

By: Engr. Shamraiz

Metal to be bent with a modulus of elasticity E = 30x106 lb/in2., yield strength Y =

40,000lb/in2 , and tensile strength TS = 65,000 lb/in2. Determine (a) starting blank size, and (b) bending force if V-die will be used with a die opening dimension D = 1.0in.

(a)W = 1.75’, and the length of the part is: 1.5 +1.00 + BA. R/t = 0.187/0.125 = 1.5 < 2.0, so Kba = 0.33

For an included angle A’ = 1200, then A = 600

BA = 2pA(R + Kbat)/360 =2p60(0.187 + 0.33 x 0.125)/360 = 0.239”

Length of the bank is 1.5+1+0.239 = 2.739”(b) Force:

F = (KbfTSwt2)/D

= 1.33 (65,000)(1.75)(0.125)2/1.0 = 2,364 lb

Bending Problem

By: Engr. Shamraiz8

Other Bending Operations

Other bending operations include:( Different from basic bending due to curved axis and other different features)a. Hemming involves bending the edge of the sheet over onto itself in more than one bending step. This process is used to eliminate sharp edges, increase stiffness, and improve appearance, such as the edges in car doors.b. Seaming is a bending operation in which two sheet metal edges are joined together.c. Curling (or beading) forms the edges of the part into a roll. Curling is also used for safety, strength, and aesthetics.

(a) Hemming(b) Seaming(c) Curling

By: Engr. Shamraiz9

Other Bending Operations

d. Flanging is a bending operation in which the edge of a sheet metal is bent at a 90° angle to form a rim or flange. It is often used to strengthen or stiffen sheet metal. The flange can be straight, or it can involve stretching or shrinking as shown in the figure below:

(a) Straight flanging(b) Stretch flanging(c) Shrink flanging

By: Engr. Shamraiz

3. Drawing Operation

Definition: Drawing is a Sheet metal forming to make cup shaped, box shaped, or other ‑ ‑complex curved, ‑ hollow shaped parts ‑ . The Sheet metal blank is positioned over die cavity and then punch pushes metal into opening.

• Products: beverage cans, ammunition shells, Cooking parts, automobile body panels

By: Engr. Shamraiz

(a) Drawing of cup shaped part: (1) ‑before punch contacts work, (2) near end of stroke; (b) workpart: (1) starting blank, (2) drawn part.

Drawing Operation

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Drawing Parameters

Clearance in Drawing• Sides of punch and die separated by a clearance c

given by: the clearance in drawing is about 10% of the stock thickness.

c = 1.1 twhere t = stock thickness

• In drawing as the punch moves downward, the stock goes under complex stresses and strains and is formed into the shape defined by punch and die.

By: Engr. Shamraiz

Drawing Parameters

Friction:The force being applied by punch is opposed by

the metal in form of deformation and friction in the operation.

• Lubricants are generally used to reduce the friction

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Drawing Parameters

Blank holding force:• If this force is too small, the wrinkling occurs.• If it is too large, it prevents metal from flowing

properly towards die cavity, resulting in stretching and possible tearing of sheet metal.

• Determining proper holding force involves a delicate balance between these opposing factor.

By: Engr. Shamraiz

Engineering Analysis of Drawing

Tests of Drawing Feasibility These tests provides information about

feasibility of the drawing operation before actually performing the operation.

1. Drawing ratio2. Reduction3. Thickness-to-diameter ratio

By: Engr. Shamraiz

Engineering Analysis of Drawing

where Db = blank diameter; and Dp = punch diameter– Upper limit: DR 2.0 (operation feasible)

1. Drawing Ratio DRThe DR measures the severity of drawing operation. The greater the ratio, the more severe the operation.

Most easily defined for cylindrical shape:

p

b

DD

DR

By: Engr. Shamraiz

Engineering Analysis of Drawing

2. Reduction R:• Defined for cylindrical shape:

b

pb

D

DDr

Value of r should be less than 0.50

3. 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

By: Engr. Shamraiz

Drawing Problem # 01

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Engineering Analysis of Drawing Drawing ForcesThe force required to perform drawing operation.

• F= Drawing Force, Db= Blank diameter, Dp= Punch Diameter• t= Original blank thickness, TS= Tensile thickness • 0.7 is correction factor to account for friction during operation

Drawing force varies throughout the downward movement of the punch and usually reaches maximum at about one-third the length of the punch stroke.

By: Engr. Shamraiz

Drawing Problem # 02

By: Engr. Shamraiz

Other Drawing Operations1. Redrawing • When too severe shape change is requires ( high drawing ratio),

complete forming may require more than one drawing steps.• The second drawing step, and any further steps required, are referred

to as redrawing. 2. Drawing without Blank holder • The blank holder is used to prevent wrinkling of the flange while cup

is being drawn.• Tendency of wrinkling reduces as t/Db ratio increases• So, when this ratio is large, the drawing can be done without blank

holders• Governed by [ 5t > Db-Dp ] • Without blank holder cost of tooling decreases and simple press can

be used.

By: Engr. Shamraiz

Other Drawing Operations

3. Shapes other than Cylindrical Cups• Many shapes other than cylinder are also drawn.• Square or rectangular boxes• 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

By: Engr. Shamraiz

Defects in Drawing1. Wrinkling in the flange• Wrinkling is a major defect in drawing operation. • The movement of the blank into the die cavity induces compressive stress in the

flange causing series of ridges radially on undrawn part of flange. • This can be reduced by keeping a blank holder under the effect of a holding force 2. Wrinkling in the wall• When the flange is drawn into cup, these ridges appears into the vertical wall.

– t/D ↑ or Fh ↑ Wrinkling ↓3. Tearing• It is an open crack in the vertical wall, usually near the base of drawn cup which is

caused due to thinning and failure of metal in this location. • It may also occur due to pulling metal over sharp die corner.

By: Engr. Shamraiz

Defects in Drawing

4. Earing • This is the formation of irregularities (called ears) in

the upper edge of the deep drawn, caused by anisotropy in the sheet metal

• If material is perfectly isotropic the earing does not occur.

5. Surface scratch• Scratches on surface of drawn parts appear when

surface of die and punch are not smooth or sufficient lubricant is not used.

By: Engr. Shamraiz

4. Other Sheet Metal Forming on Presses

In addition to bending and drawing, several other sheet metal forming operations performed on conventional presses. This includes;

1. Ironing (using metal tooling)2. Embossing (using metal tooling)3. Hydro forming (using rubber forming

approach)

By: Engr. Shamraiz

• A process which makes wall thickness of cylindrical cup more uniform and it is normally done after drawing

• Beverage canes and artillery shell are ironed to increase the life of material usage

(1) start of process; (2) during process. Note thinning and elongation of walls.

1. Ironing

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• Creates indentations in sheet, such as raised (or indented) lettering while maintaining the stock thickness uniform

Embossing: (a) cross‑section of punch and die configuration during pressing; (b) finished part with embossed ribs.

2. Embossing

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3. Hydro forming

• Hydroforming is a specialized type of die forming that uses pressurized hydraulic fluid in a diaphragm to form typical metallic sheets in to a desired shape with a die cavity. Hydroforming is a cost-effective way of shaping malleable metals such as aluminium or brass into lightweight, structurally stiff and strong pieces.

By: Engr. Shamraiz

Assignment # 02

Individual 6-pages assignment on

“Group Technology and Flexible Manufacturing System”

Last date of submission:16-05-2014

By: Engr. Shamraiz

Thank you