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In the second example in Fig. 5.11, the circular edge of the initial deep-drawn
workpiece is curled by a tool that incorporates a cavity punch.
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(5.10)
where:
M = moment of bending,
R i = inside curling radius, and
T = material thickness.
Example:
Define the curling force for the workpiece shown in fig. 5.11. Assume:
Diameter D = 400 mm,
Material thickness T = 1.2 mm,
Inner radius R i = 1.2 mm,
The ultimate tensile strength UTS = 176.5 MPa .
Solution :
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29 9 2014 Thomas Industrial Library
Known bend and curl forces often are not so important for the process because
very often, the maximum force of the press machine is greater than the
bending or curling force. However, knowing the magnitude of these forces is
necessary for a definition of the blank-holder forces. Because of the
phenomenon of material fatigue of the blank springs, these forces need to be
30 to 50 percent greater than the bending or the curling forces.
In most set-ups, short curved sections of circular work are performed on the
ends of the metal workpiece in a press brake or on a hydraulic press.
Otherwise, the workpieces would have ends that, instead of being curved,
would be straight. In the process described above, the radius of the bend
allowance is much greater than the material thickness of the workpiece; under
these conditions, the bending is entirely in the elastic-plastic domain.
To achieve permanent deformation in the outer and inner fibers of the material,
the following relationship must apply:
(5.11)
Otherwise, the workpiece, instead of being curved, will be straight after
unloading. The bending force on the upper roll is given by the formula:
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29 9 2014 Thomas Industrial Library
(5.12)
where:
D = outer diameter of the workpiece,
b = length of bend,
T = material thickness,
YS = yield stress,
E = modulus of elasticity, and
u = bend angle.
The bend angle can be calculated from the geometric ratio in Fig. 5.12 and is
given by the formula:
where:
l v = distance between lower rolls, and
d = lower rolls diameter.
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