ME2030: Manufacturing Processes 1

Metal Forming: Sheet Metal Operations

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Sheet Metal Operations

Shearing

Punching
Bending
Deep drawing
Hydroforming

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Shearing

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Shearing
Shearing is a process for cutting sheet metal to size out of a
larger stock such as roll stock. Shears are used as the
preliminary step in preparing stock for stamping processes.
Material thickness ranges from 0.125 mm to 6.35 mm (0.005
to 0.250 in). The dimensional tolerance ranges from 0.125
mm to 1.5 mm (0.005 to 0.060 in).
The shearing process produces a shear edge burr, which can
be minimized to less than 10% of the material thickness. The
burr is a function of clearance between the punch and the die
(which is nominally designed to be the material thickness),
and the sharpness of the punch and the die.
S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Dynamics

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Blanking / Punching

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Engineering Analysis: Clearance

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Clearance
c = at
c = clearance
a = allowance
t = thickness

Blanking:

Punch

Blanking punch dia. = Db- 2c

Hole punch dia. = Db

Blanking die dia. = Db

Hole die dia. = Db+ 2c

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

Clearance

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

10

Force Required
The force required for shearing is:
F = S*t*L;

where

S: shear strength of the sheet metal

t: sheet thickness
L: length of the cut edge

The shear strength S can be estimated by:

S = 0.7 * UTS; where
UTS: the Ultimate Tensile Strength

The above formula does not consider other factors such as friction
S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

11

Example
A round disk of 150-mm diameter is to be blanked

from a strip of 3.2-mm, half-hard cold rolled steel

whose shear strength = 310 MPa. Determine (a) the
appropriate punch and die diameters, and (b)

blanking force.

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

12

Sheet-metal Cutting Operations

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

13

(a) Slotting, (b) perforating, (c) notching & seminotching

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

14

Shaving and Fine Blanking

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

15

Bending
Bending is defined as the straining of metal around a straight axis. During
this process, the metal on the inside of the neutral axis is compressed,
while the metal on the outside of the neutral axis is stretched.

= bend angle
w = width of sheet
R = bend radius
S. Suryakumar, ME, IITH

t = sheet thickness
= 180 - , included angle

ME2230: Manufacturing Processes 1

16

Types of Bending
Two common bending methods are:
V-bending

Edge or wipe bending.

In V-bending the sheet metal blank is bent between a V-shaped punch and
die. The figure below shows a front view and isometric view of a V-bending
setup with the arrows indicating the direction of the applied force:

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

17

Types of Bending

Edge or wipe bending (conducted in lab) involves cantilever loading of the

material. A pressure pad is used to apply a Force to hold the blank against the die,
while the punch forces the workpiece to yield and bend over the edge of the die.
The figure below clearly illustrates the edge (wipe)-bending setup with the arrows
indicating the direction of the applied force (on the punch):

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

18

Bending Analysis

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

19

Bending Analysis

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

20

Bending Analysis
Springback is defined as the increase in included angle of the

bent part relative to the included angle of the forming tool after
the tool is removed.

After springback:
The bend angle will decrease (the included angle will increase)
The bend radius will increase

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

21

Flanging, Hemming, Seaming, and Curling

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

22

Deep Drawing

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

23

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

24

Hydroforming

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

25

Have a nice day!

S. Suryakumar, ME, IITH

ME2230: Manufacturing Processes 1

26