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Dr. J. Cecil
FORMING PROCESSES
1
Characteristics of sheet metal forming processes
2
Sheet Metal Operations - Stamping
3
Overview of Contents in this module
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Shearing
• Before a sheet metal part is made, a blank is first
removed from a large sheet by shearing
• Viz, the sheet is cut by subjecting it to shear stresses
between a punch and a die (see figure 16.2 a)
• What is sheared is normally called a slug
Figure 16.2 a
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Shearing
(c)
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Shearing Process
• Shearing starts with the formation of cracks on both the top &
bottom edges of the workpiece (Fig 16.2 --A&B, C&D regions)
• When these cracks meet each other, separation occurs
• Major parameters in shearing are:
– Shape and materials for punch and die
– Punching speed
– Lubrication
– Clearance c between punch and die
• Clearance is major factor in determining the shape and quality of
sheared edge
• As c increases, material tends to be pulled rather sheared
– Also, sheared edge becomes rougher and zone of deformation becomes
larger
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Shearing process
9
Punch Force
10
Force calculation
11
Operations
• Punching:
The sheared slug is discarded
• Blanking:
The slug is the part and rest is scrap
• Die Cutting
• Shearing process consisting of
– Perforating: punching a number of holes in a sheet
– Parting: shearing the sheet into two or more pieces
– Notching: removing pieces from the edges
– Lancing: leaving a tab without removing any material
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Operations
• Die cutting:
– Parts produced from these operations are used usually in
assembly with other components
– Eg: perforated sheet metals with hole diameters ranging from
around 1mm to 75 mm can be used as
• Filters, screen, machinery guards, for weight reduction etc.
– Punched using crank presses at rates as high as 300,000 holes
per minute (using special dies and equipment)
• Fine Blanking:
– Very smooth and square edges can be produced (fig 16.5a)
– A V-shaped stinger (or impingement) locks the sheet tightly in
place and prevents distortion (such as in fig 16.2b and 16.3)
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One set-up for fine blanking
14
Operations
FIGURE 16.10 Example of the use of shear angles on punches and dies
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Punch and Die Shapes …contd
Punched holes
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Compound Dies
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Compound Dies
FIGURE 16.11: Schematic illustrations: (a) before and (b) after blanking a common washer in a
compound die. Note the separate movements of the die (for blanki ng) and the punch (for punching
the hole in the washer). (c) Schematic illustration of making a washer in a progressive die. (d)
Forming of the top piece of an aerosol spray can in a progressive die. Note that the part is attached
to the strip until the last operation is completed.
(d)
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Compound Dies
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Progressive Dies
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Transfer Dies
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BENDING
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BENDING
25
Press Brake Forming
31
Flanging (Fig 16.25)
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Hemming
33
Roll Forming
35
Deep Drawing
36
Deep drawing (fig 16.32)
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Deep drawing Practice and guidelines
40
Embossing
• Most common materials for tools and dies are cast irons
and tool steels (carbides and plastics can be used)
• A double action hydraulic or mechanical press is widely
used
• Punch speed range is 20 ft/min and 60 ft/min
• Modern production facilities are highly automated
– Single plant can produce upto 100,000 automotive oil filter cans
per day
– Robots part handlers, lubricant sprayers and inspection systems
work together
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Rubber Forming
45
Explosive and other forming processes
• Explosive forming:
• By controlling the quantity and shape of explosives, they
can be used as a source of energy for metal forming
• First used in early 1900’s
– Typically, the sheet metal blank is clamped over a die
– the entire assembly lowered into a water tank (fig 16.44 a)
– Air in die cavity is evacuated
– Explosive charge place at certain height and detonated
– Rapid conversion of charge into gas creates a shock wave
– The pressure of this wave is enough to form sheet metals
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Explosive Forming
47
Explosive forming
– P is in PSI
– K is a constant based on explosive type (for TNT, 21,600)
– W is weight of explosive in pounds
– R is distance of explosive from workpiece surface (or Standoff)
in feet
– a is a constant taken to be usually 1.15
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Explosive forming ..contd
49
Equipment for Sheet Metal Forming
• Be prepared for quiz and exam questions
• Sample questions:
– What are the various components in a punching operation?
– Give examples of parts you use in daily life which can be
made using operations discussed in this module
– How do you estimate the punch force?
– Mention the Benefits of rubber forming
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