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FOR
SHEETMETAL WORKING
Parts are made from sheet metal in two
fundamentally different ways.
where
Cds=die set purchase cost, $
AU = usable area, cm
• The die set “cost” is represented as an equivalent
number of tool making hours.
Mdsu = 3+0.009Au
• The basic manufacturing points were found to be
determined by the size of the punch and by the
complexity of the profile to be sheared.
• Profile complexity is measured by index Xp
XP = P/(LW)1/2
Where
P=perimeter length to be sheared, cm
L, W=length and width of the smallest rectangle
that surrounds the punch, cm.
• basic die-manufacturing hours associated with
perimeter complexity to be
Mp0 = fd(28+1.03Xp)
where
fd = die-type factor
fd=1.0 for a blanking die,
fd=0.91 for a part-off die,and
fd=0.88 for a cut-off die.
die plate thickness
hp = 9+2.5log((U/Ulc)Vh)mm
where
• U= ultimate tensile stress of the sheet metal to
be sheared
• Ulc = ultimate tensile stress of annealed low-
carbon steel
• V= required production volume, expressed in
thousands
• h = sheet metal thickness, mm.
• The manufacturing points obtained were
determined for the condition
(U/Ulc)Vh2 = 625
or
hp=25mm
Mpo = 23+0.03LW
where
L, W= length and width of the rectangle that
encloses all the holes to be punched, cm
The total manufacturing points for a piercing die
as
Mp = 34+0.039LW+0.6Pp+3Np
where
1. V-Die
2. Wiper Die
V-DIE
• This is the least expensive type of bending die,
but it suffers because of the difficulty of precisely
positioning the metal blank and a resulting lack
of precision in the bent part
WISPER DIE
• It allows greater control of bend location on the
part.
Cpd = 2Cid
where
Where
U = ultimate tensile strength, kN/m2
h = gage thickness, m
ls= length to be sheared, m
CYCLE TIME
t = 3.8 + 0.11(L+W) s
DESIGN RULES
• For parts that are to be manufactured with
dedicated dies, it is advantageous to design the
outer profile with parallel straight edges defining
the part width.