Sheet metal forming

processes

Sheet metal forging:

-

Products include metal desks, car bodies, food cans.

Low carbon steel is the most commonly used according to its low cost
and good strength.

Shearing operations:
Piercing and Blanking:
-

In punching (piercing), the sheared slug is discarded.

In blanking, the slug is the part and the rest is scrap.
Blanking

Shearing:

( C)
Distortion area

Smooth & shiny

Hole
Slug

As the clearance c increases, the deformation zone becomes

larger.
Clearances generally range between 2% and 8% of the sheet thickness.

Increases by increasing clearance

Increases by increasing ductility

Fine blanking:
-

Very smooth and square edges can be

produced by fine blanking.
A V-shaped stinger locks the sheet tightly in
place and prevents distortion.
Clearance is nearly 1% of the sheet
thickness.
Movements of the punch, pressure pad, and
the die are separately controlled.

Comparison between shearing (blanking) and fine blanking:

Shearing process

Fine blanking process

- Clearances generally range

between 2% and 8% of the
sheet thickness.

- Clearance is nearly 1% of the

sheet thickness.
Very smooth and square edges
can be produced.
A V-shaped stinger locks the
sheet and prevents distortion.

Punch force:

Lateral area

F T .L.(USS )
Ultimate shear strength

F 0.75T .L.(UTS)

For steels

USS 0.75(UTS)

Where T is sheet thickness, L is the total length sheared (such as the perimeter
of a hole), and UTS is the ultimate tensile strength of the material.

Example:
Estimate the force required for punching a 25 mm diameter hole through a
3.2 mm thick annealed titanium alloy sheet at room temperature. Given
that UTS is 1000MPa

F 0.75T (D)(UTS) 0.75(3.2)( )(25)(1000) 170KN

Example:
Estimate the force required for punching a 25 mm diameter hole through a
3.2 mm thick annealed titanium alloy sheet at room temperature. Given
that ultimate shear strength is 700MPa

F T (D)(USS ) (3.2)( )(25)(700) 170KN

Spinning:
-

Forming of axis-symmetric parts over a mandrel, by the use of various tools

and rollers.

Conventional spinning:
-

A circular blank is held against a mandrel and rotated.

A rigid tool deforms and shapes the material over the mandrel.
The tool may be activated either manually or by hydraulic mechanism.
The process involves a sequence of passes, and it requires considerable skill.
Part diameters may range up to 6m.
Most spinning is performed at room temperature, while thick parts, or
metals with high strength or low ductility, require spinning at elevated
temperatures.

Show video

Bending sheet and plate:

-

The outer fibers of the material are in tension, while the inner fibers are in
compression.
The bend allowance is the length of the neutral axis in the bend and is
used to determine the blank length for the bent part.

ri

Show video

Types of bending processes:

Roll bending

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Die bending processes:

1)
2)
3)
4)

Acute die
Gooseneck
Offset
Rotary

Die bending (V-bending)

Die bending (U-bending)

Main principals of bending operation:

Minimum bend radius

Spring back

The minimum bend radius:

-

As r/S decreases , the material eventually cracks.

The minimum bend radius is usually expresses in terms of the thickness such
as 0.5s, 0.6s,..and so on. Thus, a 0.6s minimum bend radius indicates that
the smaller radius to which the sheet can be bent, without cracking, is
0.6 times its thickness.

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The minimum bend radius (for Die bending- U or V die):

-

Bend radius should not be smaller than 0.6S. With harder material, it should
be equal to the sheet thickness.
Material coefficient

rmin S.c
Sheet thickness
Smallest permissible bend radius

The minimum bend radius (for Roll bending):

Modulus of elasticity

rmin

E
S.
2 Re
Yield strength

The effect of elongated sheets on cracking:

Longitudinal direction

cracks

Longitudinal

As r/S decreases , the material eventually cracks.

Transverse

Example:
If it is required to bend a sheet of thickness 3mm using V-die, sheet material is Cu
(hardened), find the smallest bend radius.

The bend axis is longitudinal to the rolling direction:

rmin S.c (3)(2) 6mm

The bend axis is Transverse to the rolling direction:

rmin S.c (3)(1) 3mm

Spring-back:
-

Because all materials have a finite modulus of elasticity, plastic deformation

is follower, when the load is removed, by some elastic recovery.

Spring-back:
Required angle

Die angle

Spring back angle

Yield strength

Re

Re

Example:
A V-die is used to bend a sheet of thickness 1mm. If bend angle is required to be
110 degrees, find the angle of V-die used to obtain the required angle.
Required angle

Die angle

Spring back angle

110o 3o 107o
Die angle

Deep drawing:
-It involves a combination of bending and
stretching of sheet metal blanks.

Show video
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Determining the blank size for cylindrical parts with small

radii (r<10 mm):
a) Cup without flange:

D 2 . d 2 .

d . .h
4
4
D d 2 4dh
b) Cup with flange:

D 2 . d12 .
2
2

d1. .h (d 2 d1 )
4
4
4
D 2 . 2
(d1 4d1.h d 22 d12 )
4
4
D d 22 4d1h
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Formulae for calculating the blank diameter of various shapes:

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Defects during deep drawing:

a) Wrinkled extra flange with

horizontal cracks beneath it:
-

Too high die edge

curvature, too low
blank holder
pressure.

b) Earring on one side of the wall edge or on the sheet flange:

-

Blank inserted off center.

Irregular blank holder
pressure.

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c) Tearing in the corners of rectangles, starting out at the edge

and moving down towards the bottom corner:
-

Lack of material in the

corners due to incorrect
blank size.
Drawing clearance too
narrow in the corners.

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Machining Processes

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Introduction: General aspects of machining technology:

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Introduction: Classification of machining processes:

Cutting

Abrasion

Erosion

Machining
allowance
is
removed in the form of
visible chips

Machining
allowance
is
removed in the form of very
small chips by hard randomly
oriented abrasive grit of
indefinite number and shape

Machining allowance is removed in the form of successive

surface layers as a result of dissolution, melting and
vaporization of the material being machined

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Machining by cutting

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1.Turning Operation
-Turning is the process of generating axis-symmetrical
surfaces by cutting.

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34

Turning operation:
-Turning is the process of generating axis-symmetrical surfaces
by cutting.
Motion 1 (cutting motion):The work piece rotates about its axis.

Motion 2 (feed motion):-The tool moves slowly at a constant

speed parallel to the required profile of work piece.
Motion 3(depth of cut):-Before starting with the feed motion, the
tool must be moved radial to the desired depth of cut.

Depth of cut

Depth of cut

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Lathe (Turning operation):

Tool post

Chuck

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Work-piece fixation:

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Work piece holding

-Three jaw chuck: If we are tightening or loosening any jaw, all the three jaws
come towards or away the center with equal distances.
-It is used for holding round work.

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Work piece holding

-Four jaw chuck: The jaws are driven by individual square thread screws, and
will hold irregular work internally or externally.

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Work piece holding

Face plate:

It contains open slots or T slots so that bolt can be used to clamp the work of
complicated shape and size, which cannot be held in a chuck.

Head stock

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Workpiece

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Work piece holding

Between centers:

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Tool holding
(Tool post)

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Operations on a center
lathe

1. Plain turning:

Required product
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Original workpiece

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2. Step turning:

2nd

Required product
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1st depth of cut

depth of cut

Original workpiece

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3. Face turning:

4. Threading:

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5. Taper turning:
- Offsetting tail stock:
Angle of taper should not exceed 8 degrees.

-Form (straight edge) tool:

Tool width exceeds the taper being turned.
Length of work piece less than or equal 10mm.

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5. Taper turning:
-Compound rest :
Tool is fed manually by rotating handle.
This method used for turning large taper angles.

6. Undercutting or grooving:

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7. Boring:

Boring head
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8. Drilling:

9. Reaming:

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Terms used in lathe machining

Cutting speed V (m/min): The speed at which the metal is removed
by the tool.

Dn

1000

m / min

V: Cutting speed (m/min)

D: Initial work-piece diameter (mm)
n: Number of revolutions per minute (rpm)
Feed f (mm/rev): The distance which the tool
advances (axially)for each revolution.

Depth of cut td (mm): The depth of penetration of

the tool into the work-piece during machining for
one pass.
Dd

td

mm

Depth of cut

d: Final diameter (mm) after one pass.

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If more than one pass, the number of required passes n is:

no.

total

reduction
2td

D d final
2t

Reduction in diameter in one pass

Example: The diameter of a 50 mm steel bar is reduced to 46 mm

through plain turning. The spindle speed is 580 rpm, the length of
work-piece is 150mm, depth of cut is 1 mm, and the feed is 0.1
mm/rev. Calculate:
-Required number of turning passes.
Total reduction in diameter D d final

50 46 4mm

4mm
Number of passes
2 passes
2td
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l a l lo
L
tm

f .N
f .N
t m Machining time
f

Feed (mm/rev)

la Length of approach
l Length of cutting
lo Length of overrun
If l 200mm la , lo may be neglected .

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Machining time
L
tm
f .n

min
The machined length in one minute

Example: Calculate the machining time required for cylindrical

turning of 10 shafts, each with 30 mm diameter and 400 mm long.
Knowing that the cutting speed for the material = 20 m/min. and the
feed rate = 0.1 mm/rev.

.D.n

1000
(30)n
20
, n 20000 / 30
1000
t m (400) /( 0.1)(n) 19 min
t m (total ) 19 *10 190 min .
Dr. Soheir Backar

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