Sheet Metal Forming Processes

Sheet metal Forming processes
Chapter 8:
KSU - College of Engineering - IE Chapter 8: Sheet Metal Forming

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Department Processes
Chapter 8: Sheet Metal Forming
CHAPTER Eight: Sheet Metal Processes
8.1 Deep drawing and Stretch drawing processes

8.2 Sheet metal shearing processes
Processes
8.3 Sheet metal bending processes
Department
KSU - College of Engineering - IE
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8.1 Sheet Metal Deep Drawing Process Technology

Processes Department
Definition: In deep drawing, as a first step, a cup is produced from the flat
blank. This cup can then be further processed, for example by an additional
drawing, reverse drawing, ironing or extrusion process.
In all deep drawing processes, the pressing force is applied over the draw punch
onto the bottom surface of the drawn part.
It is further transferred from there to the perimeter in the deformation zone, 3
between the die and the blank holder.
8.1 Sheet Metal Deep Drawing Process Technology.. continue

The work piece is subjected to radial tension forces FR and tangential compression
forces FT.
The material is compressed in the tangential direction and stretched in the radial
direction.
As the draw depth is increased, the amount of deformation and the deformation
resistance are also increased.
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8.1 Sheet Metal Deep Drawing Process Technology.. continue

Deep drawing with rigid tooling, involving draw punches, a blank holder and a
female die. The blank is generally pulled over the draw punch into the die, the
blank holder prevents any wrinkling taking place in the flange.
In pure deep drawing, the thickness of the sheet metal remains unchanged since
an increase in the surface area does not occur, as it occurs in a stretch drawing
process.
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8.1 Sheet Metal Deep Drawing Process Technology .. continue

Processes
Deep drawing and
stretching processes
Department
Unlike in deep drawing, in stretch forming the sheet metal cannot flow because it is
gripped by clamps or held in a blank holder. The forming process takes place with a
reduction in the thickness of the sheet metal. Pure stretch drawing is a forming process
conducted under tensile stresses. 6
8.1.1 Deep Drawing Processes

There are basically three possible ways of applying blank holder force , this lead us to
three type of deep drawing processes.
1) Double action deep drawing process
Processes
2) Single action deep drawing process
3) Counter drawing or reverse drawing process
Department
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1) Double action deep drawing 4
process
In double-action drawing
operations the press has two
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Processes
slides acting from above: the
drawing slide with the draw
punch and the blank holder slide
Department
with the blank holder.
The blank-holding slide
transfers the blank-holding force
via the blank holder onto the 2 3
blank and the draw die.
The die and the ejector are
located in the lower die on the
press bed
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2) Single action deep drawing
process
Single-action drawing with a
draw cushion works the other
Processes
way round the forming force is
exerted by the slide above
1 4
through the die and the blank
Department
holder onto the draw cushion in
the press bed.
The draw punch and the blank
holder of the drawing tool are
both located in a base plate on
the press bed.
Pressure pins, which come up
through the press bed and the 2
base plate transfer the blank 3
holder force from the draw 9
cushion onto the blank holder.
8.1.1 Deep Drawing Processes ?

3) Counter drawing or reverse drawing
process
Energy is saved and cost-effective
alternative in stamping using counter
Processes
drawing process.
The top die is attached to the slide. The
lower die is mounted on the press bed
Department
with the blank holder. The punch is
located in an opening in the center of
the press bed on the draw cushion.
During deformation, the blankholding
force is transferred via the slide from
above and the draw punch force acts
from below through the active draw
cushion. The punch forms the part by
means of its upward movement while
the blank holder rests on the die, see Fig 10
8.5.
8.1.2 Calculation of the blank size in deep drawing:

Before starting drawing operations
the size and form of the blank must
be determined for the desired final
part geometry and die layout.
This should be shown using the
Processes
example of a simple rotationally
symmetrical body.
Department
In order to calculate the blank
diameter, volume constancy in metal
forming is used. Hence, the entire ax-
symmetric part is divide into various
individual ax symmetric components, D
in accordance with Table 8.1a and
then calculate the surface areas of
these components.
The total surface area as a sum of
the individual areas enables the 11
calculation of the diameter of blank
D.
8.1.2 Calculation of the blank size in deep drawing:

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8.1.2 Calculation of the blank size
in deep drawing:

More cases in Table 8.1b,c and d
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8.1.3 Calculation Drawing Ratio:

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8.1.4 Calculation Drawing Force

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8.1.5 Calculating Blank Holding Force

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8.1.6 Calculating Drawing Energy

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8.2 Shear and Hole Stamping Products

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8.2.1 Sheet Metal Shearing Process

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8.2.1 Sheet Metal Shearing Process .. continue
Punch and die are made from hardened alloy steel to resist wear.

In operation the punch is pressed down on to the sheet material exerting
a shear load which exceeds the shear strength of the material, and thus
shears out the part, pushing it through the die. The stripper plate is
provided to prevent retention of the material on the punch when the
press is raised.
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8.2.1 Sheet Metal Shearing Process Blanking .. continue

Blanking of this sort is carried out in
a single action crank press. This press
is driven by a motor which drives a
flywheel. When the operator engages
Processes
the clutch the rotating flywheel is
coupled to the crankshaft, which
rotates driving the ram of the press
Department
downwards.
The energy stored in the flywheel
provides the force necessary to push
the punch into the die and then returns
the punch to the starting position,
where upon the clutch disengages and
the motor drives the flywheel up to
speed ready for the next stroke,
replacing the energy used in the 24
blanking operation.
8.2.1 Sheet Metal Shearing Process Blanking Applications .. continue

Blanking die of screw washer
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Complex Banking die set for complex parts

8.2.1 Sheet Metal Shearing Process - Blanking .. continue
Figure 8.12 shows the progressive deformation and the development of a
shear fracture during the shearing process, together with a typical load-

penetration graph [].
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8.2.1 Sheet Metal Shearing Process Blanking .. continue

The effect of clearance on the
piercing of a moderately ductile
metal which work hardens and
begins to develop cracks at an
early stage of penetration.
Processes
If the clearance is suitable the
cracks run one into the other. The
resulting hole is slightly tapered,
Department
the work done in shearing is
somewhere near minimum, but
the maximum load on the punch
is almost independent of the
clearance and is given by:
Pmax = metal thickness (t) x

perimeter x ultimate shear stress
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of sheet
8.2.1 Sheet Metal Shearing Process Blanking - Decreasing shearing load .. continue

Two common techniques used to decrease shearing load
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Single shear in punch Double shear in punch

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8.3 Sheet metal bending technology

Bending is a manufacturing process by
which sheet metal can be deformed by
plastically deforming the material and
changing its shape. The material subjected
Processes
to stresses beyond its yielding and below its
ultimate tensile strength. There is little
change in surface area, about bend axis.
Department
Bending is a flexible process by which a
varity of different shapes can be produced
through the use of standard die sets on
bend break. The material is placed on the
die, and positioned in place with stops
and/or gauges. It is held in place with hold
downs, where the upper part of the press is
the ram with appropriately shaped punch
descends and forms the blank 30
longitudinally, see Fig 8.15.
8.3 Sheet metal bending processes

Bending is done using Press Brakes, which is
hydraulic press with variable loading
capacity from 20 to 200 tons and with stock
length from 1meter to 4.5 meters.
Processes
Bending also can be down using rotating
rolls called roll bending machine, see Fig
Department
8.16. Rotating rolls also can be used to
straighten the rod or sheet metal, see Fig
8.17. Bending also can be carried on
tandem rolling stands to bend the sheet
metal in incremental stages (roll forming
process), see Fig 8.18. There are also other
special bending processes, like swivel
bending, circular bending, tube bending,
..etc., see Fig 8.19
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Sheet Metal Forming Processes

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Sheet metal Forming processes

KSU - College of Engineering - IE Chapter 8: Sheet Metal Forming

8.1 Deep drawing and Stretch drawing processes

Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

1) Double action deep drawing process

Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

KSU - College of Engineering - IE Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

KSU - College of Engineering - IE Chapter 8: Sheet Metal Forming

KSU - College of Engineering - IE Chapter 8: Sheet Metal Forming

KSU - College of Engineering - IE Chapter 8: Sheet Metal Forming

KSU - College of Engineering - IE Chapter 8: Sheet Metal Forming

KSU - College of Engineering - IE Chapter 8: Sheet Metal Forming

KSU - College of Engineering - IE Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

Complex Banking die set for complex parts

Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

Pmax = metal thickness (t) x

Chapter 8: Sheet Metal Forming

Single shear in punch Double shear in punch

Chapter 8: Sheet Metal Forming

Chapter 8: Sheet Metal Forming

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