Sheet Metal Working

Dr. Mirza Jahanzaib

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 Defined
• Sheet metal working includes cutting
and forming operations performed
on relatively thin sheets of metal.
• Typical thickness are b/w 0.4mm
(1/64 in) and 6mm (1/4 in).

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 Process of
Sheet Metalworking
• Cutting Operations
• Bending Operations
• Drawing
• Other Sheet Metal Forming Operations
• Dies and Presses for Sheet Metal Processes
• Sheet Metal Operations Not Performed on
Presses
• Bending of Tube Stock

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 Sheet and Plate Metal Products
• Sheet and plate metal parts for industrial and
Consumers 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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 Some Advantages of Sheet Metal
Parts
• High strength
• Good dimensional accuracy
• Good surface finish
• Relatively low cost
• For large quantities, economical mass
production operations are available

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 Sheet Metalworking Terminology
1. Punch-and-die
 Tooling to perform cutting, bending, and drawing
2. Stamping press
 Machine tool that performs most sheet metal
operations
3. Stampings
 Sheet metal products

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 Three Major Categories of
Sheet Metal Processes
1. Cutting
 Shearing to separate large sheets; or cut part
perimeters or make holes in sheets
2. Bending
 Straining sheet around a straight axis
3. Drawing
 Forming of sheet into convex or concave shapes

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•Rollover: corresponds to
the depression made by the
punch in the work prior to
cutting, it is place where
plastic deformation begins
•Burnish: Relatively
smooth region below
rollover. This results from
penetration of the punch
into the work before
fracture begins
•Fractured zone: a rough
surface, where downward
movement of the punch
caused fracture of metal
•Burr: a sharp corner on
the edge caused by
elongation of the metal
during final separation of
two pieces
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 Cutting

Shearing between two

sharp cutting edges

Shearing of sheet metal

between two cutting
edges:
(1) just before the punch
contacts work

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Shearing of sheet metal
between two cutting
edges:
(2) punch begins to
push into work,
causing plastic
deformation

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Shearing of sheet
metal between two
cutting edges:
(3) punch compresses
and penetrates
into work causing a
smooth cut surface

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Shearing of sheet metal
between two cutting
edges:
(4) fracture is initiated at
the opposing cutting
edges which separates
the sheet

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 Shearing, Blanking, and Punching
Three principal operations in pressworking that
cut sheet metal:
• Shearing
• Blanking
• Punching

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 Shearing
Sheet metal cutting operation along a straight
line between two cutting edges
• Typically used to cut large sheets into smaller
sections for subsequent operations

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 Shearing operation:
(a) side view of the shearing operation
(b) front view of power shears equipped with inclined upper
cutting blade Symbol v indicates motion

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 Blanking and Punching
Blanking - sheet metal cutting to separate piece
from surrounding stock
• Cut piece is the desired part, called a blank
Punching - sheet metal cutting similar to
blanking except cut piece is scrap, called a
slug
• Remaining stock is the desired part

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(a) Blanking and (b) punching

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 Clearance in Sheet Metal Cutting

Distance between the punch and die

• 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 strained between cutting
edges and excessive burr results

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• Recommended clearance can be calculated
by:
c = at
where c = clearance; a = allowance; and t = stock
thickness

• Allowance ‘a’ is determined according to type

of metal

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 Allowance ‘a’ for
Three Sheet Metal Groups

Metal group a
1100S and 5052S aluminum alloys, all 0.045
tempers
2024ST and 6061ST aluminum alloys; brass, 0.060
soft cold rolled steel, soft stainless steel

Cold rolled steel, half hard; stainless steel, 0.075

half hard and full hard

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 Punch and Die Sizes for
Blanking and Punching
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

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Die size determines blank size Db;
Punch size determines hole size Dh;
c = clearance 26
 Problem
A blanking operation is to be performed
on 2.0 mm thick cold rolled steel (half
hard). The part is circular with diameter =
75.0 mm. Determine the appropriate
punch and die sizes for this operation.

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 Solution
From Table, a = 0.075. Thus,
c = 0.075(2.0) = 0.15 mm.
Punch diameter = Db - 2c
= 75.0 - 2(0.15)
= 74.70 mm

Die diameter = Db = 75.0 mm

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 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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 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

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 Problem 2
Determine the blanking force required
for 2.0 mm thick sheet, if the steel has a
shear strength = 350 MPa
Solution:
F = StL
Previous problem

t = 2.0 mm
L = 3.1415 x D = 75 x 3.1415 = 235.65 mm

F = 350(2.0)(235.65) = 164,955 N

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 Bending
Straining sheet metal around a straight axis to
take a permanent bend

(a) Bending of sheet metal

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Metal on inside of neutral plane is compressed, while
metal on outside of neutral plane is stretched

(b) both compression and tensile elongation of the metal occur in bending
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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 press brake
• V-dies are simple and inexpensive

(a) V-bending

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 Edge Bending
• For high production
• Pressure pad required
• Dies are more complicated and costly

(b) edge bending (wiping die)

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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 = specified dimension

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 Bend Allowance Formula
A
BA  2 (R  K bat )
360
where BA = bend allowance; A = bend angle;
R= bend radius; t = stock thickness; and Kba
is factor to estimate stretching
• If R < 2t, i.e. (R/t)<2; Kba = 0.33
• If R  2t, i.e. (R/t )> 2; Kba = 0.50

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 Problem 3
A bending operation is to be performed on
4.75 mm thick cold rolled steel. The part
drawing dimensions are A’ = 45 degree.
Determine the blank size required, R=9.5
mm, w=32mm
Solution
t = 4.75 mm, A’ = 45 degree

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Dimensions of starting blank: w = 32 mm (given)

L = 50 + 27.98 + 37.5 = 115.48 mm

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 Springback in Bending
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

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Springback in bending shows itself as a decrease in bend
angle and an increase in bend radius:
(1) during bending, the work is forced to take the radius Rb
and included angle Ab' of the bending tool (punch in
V-bending),
(2) After punch is removed, the work springs back to radius R
and angle A' 42
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 Bending Force
Maximum bending force estimated as follows:
2
K bf .TS .w.t
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
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Die opening dimension D: (a) V-die, (b) wiping die

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 Deep 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

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Figure
(a) Drawing of a cup
shaped part:

(1) start of operation

before punch contacts
work

(1) near end of stroke

(b) Corresponding work

part:
(1) starting blank
(2) drawn part
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 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 = about 10% greater
than stock thickness

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 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 = 2.0
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 Reduction r
• Again, defined for cylindrical shape:

Db  Dp
r 
Db

• Value of r should be less than 0.50

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 Thickness-to-Diameter Ratio

Thickness of starting blank divided by blank

diameter
Thickness-to-diameter ratio = t/Db
• Desirable for t/Db ratio to be greater than 1%
• As t/Db decreases, tendency for wrinkling
increases

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 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

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 Problem 4

A cup is to be drawn in a deep drawing operation.

The height of the cup is 75 mm and its inside
diameter = 100 mm. The sheet metal thickness
= 2 mm. If the blank diameter = 225 mm,
Determine: (a) drawing ratio, (b) reduction, and (c)
thickness-to-diameter ratio. (d) Does the
operation seem feasible?

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 Solution

(d) Feasibility? No! DR is too large (greater than

2.0), r is too large (greater than 50%), and t/D is too
small (less than 1%).

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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

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 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

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 Ironing
• Makes wall thickness of cylindrical cup more uniform
• Examples: beverage cans and artillery shells

Ironing to achieve a more uniform wall thickness in a drawn

cup: (1) start of process; (2) during process
Note thinning and elongation of walls
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 Embossing
• Used to create indentations in sheet, such as raised
(or indented) lettering or strengthening ribs

Embossing: (a) cross-section of punch and die configuration during

pressing; (b) finished part with embossed ribs

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 Guerin Process

Guerin process: (1) before and (2) after

Symbols v and F indicate motion and applied force respectively

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 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

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 Dies for Sheet Metal Processes

Most press working operations performed with

conventional punch-and-die tooling
• Custom-designed for particular part
• The term stamping die sometimes used for
high production dies

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Components of a punch and die for a blanking
operation 63
(a) Progressive die;
(b) associated strip
development

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 Sheet Metal Operations
Not Performed on Presses
• Stretch forming
• Roll bending and forming
• Spinning
• High-energy-rate forming processes.

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 Stretch Forming
Sheet metal is stretched and simultaneously
bent to achieve shape change

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

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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
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 Roll Bending
Large metal sheets and plates are formed into
curved sections using rolls

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 Roll Forming
Continuous bending process in which opposing
rolls produce long sections of formed shapes
from coil or strip stock

Roll forming of a
continuous
channel
section:
(1) straight rolls
(2) partial form
(3) final form

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 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

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Conventional spinning: (1) setup at start of process; (2) during spinning;
and (3) completion of process

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 Effect of Anisotropic sheet
properties on formability

• Self study

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 Conclusion

• Understand sheet metal working

• Solve the problem sheet to grasp concept

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