Manufacturing Technology I

ME 303
Chapter 20
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
References:
Fundamentals of Modern Manufacturing:
materials, processes, and systems, 4th Ed., by
Mikell P. Groover, JOHN WILEY & SONS, INC.,
2010. (Chapter 20, pages 443-450)

2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
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
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Sheet-Metal Forming Processes
Sheet-Metal Parts
(a) (b)
Figure 16.1 Examples of sheet-metal parts. (a) Die-formed and cut stamped parts. (b) Parts produced
by spinning. Source: (a) Courtesy of Aphase II, Inc. (b) Courtesy of Hialeah Metal Spinning, Inc.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Sheet Metalworking Defined
Cutting and forming operations performed on
relatively thin sheets of metal
Thickness of sheet metal = 0.4 mm (1/64 in) to
6 mm (1/4 in)
If thickness of stock > 6 mm it is reffered as
plate plate.
Operations usually performed as cold working
Warm working- when the stock is thick, the
metal is brittle, or the deformation is significant.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Sheet and Plate Metal Products
Sheet and plate metal parts for consumer and
industrial 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
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Advantages of Sheet Metal Parts
High strength
Good dimensional accuracy
Good surface finish
Relatively low cost
Economical mass production for large
quantities
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Sheet Metalworking Terminology
Punch-and-die (Stamping die)- tooling to
perform cutting, bending, and drawing
Stamping press - machine tool that
performs most sheet metal operations
Stampings - sheet metal products
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Basic Types of Sheet Metal Processes
Cutting
Shearing to separate large sheets
Blanking to cut part perimeters out of
sheet metal
Punching to make holes in sheet metal
Bending
Straining sheet around a straight axis
Drawing
Forming of sheet into convex or concave
shapes
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Figure 20.1 Shearing of sheet metal between two cutting edges:
(1) just before the punch contacts work; (2) punch begins to
push into work, causing plastic deformation;
Sheet Metal Cutting
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Figure 20.1 Shearing of sheet metal between two cutting edges:
(3) punch compresses and penetrates into work causing a
smooth cut surface; (4) fracture is initiated at the opposing
cutting edges which separates the sheet.
Sheet Metal Cutting
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Fig 20.2 Characteristic sheared edges of the work
Shearing with a
Punch and Die
Figure 16.2 (a) Schematic illustration of
shearing with a punch and die, indicating
some of the process variables. Characteristic
features of (b) a punched hole and (c) the
slug. (Note: The scales of the two figures are
different.)
Punch force, F= 0. 7TL UTS
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Shearing, Blanking, and Punching
Three principal operations in pressworking that
cut sheet metal:
Shearing
Blanking
Punching
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Shearing
Sheet metal cutting operation along a straight line
between two cutting edges
Typically used to cut large sheets






Figure 20.3 Shearing operation: (a) side view of the
shearing operation; (b) front view of power shears
equipped with inclined upper cutting blade.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Blanking and Punching
Blanking - sheet metal cutting along a closed
outline in a single step to separate piece
(called a blank) from surrounding stock
Punching - similar to blanking except cut piece is
scrap, called a slug








Figure 20.4 (a) Blanking and (b) punching.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
ENGINEERING ANALYSIS OF SHEET-
METAL CUTTING
Process parameters in sheet metal cutting are:

clearance between punch and die
Stock thickness
type of metal
Strength of metal, and
length of the cut
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Material saving by using more than one row
Efficient Part Nesting for Optimum Material Utilization
Figure 16.51 Efficient nesting of parts for optimum material utilization in blanking.
Source: Courtesy of Society of Manufacturing Engineers.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Clearance in Sheet Metal Cutting
Distance between punch cutting edge and die
cutting edge
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 pinched between cutting edges and
excessive burr results
In special operations requiring very straight
edges, such as shaving and fine blanking,
clearance is only about 1% of stock thickness.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Fig 20.5 Effect of clearance: (a) clearance too small causes less-
than-optimal fracture and excessive forces; and (b) clearance too
large causes oversized burr. Symbols v and F indicate motion and
applied force, respectively
Shearing
Figure 16.3 (a) Effect of the clearance, c, between punch and die on the deformation zone in
shearing. As the clearance increases, the material tends to be pulled into the die rather than be
sheared. In practice, clearances usually range between 2 and 10% of the thickness of the sheet. (b)
Microhardness (HV) contours for a 6.4-mm (0.25-in.) thick AISI 1020 hot-rolled steel in the sheared
region. Source: After H.P Weaver and K.J. Weinmann.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Clearance in Sheet Metal Cutting
Recommended clearance is calculated by:
c = at
where c = clearance; a = allowance; and t =
stock thickness
Allowance a is determined according to type of
metal
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Sheet Metal Groups Allowances
Metal group a
1100S and 5052S aluminum alloys, all
tempers
0.045
2024ST and 6061ST aluminum alloys;
brass, soft cold rolled steel, soft
stainless steel
0.060

Cold rolled steel, half hard; stainless
steel, half hard and full hard
0.075
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Punch and Die Sizes
Whether to add the clearance value to the
die size or subtract it from the punch size
depends on whether the part being cut out
is a blank or a slug.
Because of the geometry of the sheared
edge, the outer dimension of the part cut
out of the sheet will be larger than the
hole size.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Figure 20.6 Die size
determines blank
size D
b
; punch size
determines hole
size D
h
.; c =
clearance
Punch and Die Sizes
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Punch and Die Sizes
For a round blank of diameter D
b
:
Blanking punch diameter = D
b
- 2c
Blanking die diameter = D
b

where c = clearance
For a round hole of diameter D
h
:
Hole punch diameter = D
h
Hole die diameter = D
h
+ 2c
where c = clearance

2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Purpose: allows slug or blank to drop through die
Typical values: 0.25 to 1.5 on each side
Figure 20.7
Angular
clearance.
Angular Clearance
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Cutting Forces
Important for determining press size (tonnage)
F = S t L
where S = shear strength of metal; t = stock
thickness, and L = length of cut edge (the
perimeter length of the blank or hole being cut.)
If shear strength is unknown
(22.5)

where TS = ultimate tensile strength, MPa.
It is assumed here that the entire cut along the
sheared edge length L is made at the same
time.
F=0. 7 TS tL
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Cutting Forces
These equations assume that the entire cut
along the sheared edge length L is made at the
same time.
The maximum force is reduced by using an
angled cutting edge on the punch or die.
The angle (shear angle), spreads the cut over
time and reduces the force experienced at any
one moment.
However, the total energy required is the same.
Shear Angles
Figure 16.10 Examples of the use of shear angles on punches and dies.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Example 20.1
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.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
OTHER SHEET-METAL-CUTTING
OPERATIONS
FIGURE 20.8 (a)Cutoff and (b)
parting.
Cutoff:
shearing operation in which blanks are separated
from a sheet-metal strip by cutting the opposite sides of
the part in sequence.
1.The cut edges are not necessarily straight.
2.The blanks can be nested on the strip in such a way
that scrap is avoided.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
OTHER SHEET-METAL-CUTTING
OPERATIONS
FIGURE 20.8 (a)Cutoff and (b)
parting.
Parting:
Cutting a sheet-metal strip by a punch with two cutting edges
that match the opposite sides of the blank.
the part outline has an irregular shape that precludes perfect
nesting of the blanks on the strip.
less efficient than cutoff as it results in some waste material.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
OTHER SHEET-METAL-CUTTING
OPERATIONS
FIGURE 20.8 (a)Cutoff and (b)
parting.
Slotting:
punching operation that cuts out an elongated or
rectangular hole.
Perforating:
simultaneous punching of a pattern of holes in sheet
metal.
Notching:
Cutting out a portion of metal from the side of the sheet
or strip.
Seminotching removes a portion of metal from the
interior of the sheet.
Seminotching creates part of the blank outline, while
punching and slotting create holes in the blank.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Fig 20.9 (a) Slotting, (b) perforating, (c) notching and
seminotching. Symbol v indicates motion of strip.
Die-Cutting Operations
Figure 16.4 (a) Punching (piercing) and blanking. (b)
Examples of various die-cutting operations on sheet metal.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
OTHER SHEET-METAL-CUTTING
OPERATIONS
FIGURE 20.8 (a)Cutoff and (b)
parting.
Triming:
Cutting operation performed on a formed part to remove
excess metal and establish size.
Shaving:
A shearing operation performed with very small
clearance to obtain accurate dimensions and cut edges
that are smooth and straight.
It is typically performed as a secondary or finishing
operation on parts that have been previously cut.
Fine Blanking:
A shearing operation used to blank sheet-metal parts
with close tolerances and smooth, straight edges in one
step.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Fig 20.10 (a) Shaving, and (b) fine blanking. Symbols: v = motion
of punch, Fh = blank holding force
The Shaving Process
Figure 16.9 Schematic illustrations of the shaving process. (a) Shaving a sheared edge. (b)
Shearing and shaving combined in one stroke.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Conventional Versus Fine-Blanking
Figure 16.5 (a) Comparison of sheared edges produced by conventional (left) and by fine-
blanking (right) techniques. (b) Schematic illustration of one setup for fine blanking.
Source: Courtesy of Feintool U.S. Operations.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e



Other methods of cutting sheet metal: band saw;
flame cutting; plasma cutting; laser-beam cutting;
friction sawing; water-jet cutting (water-jet
machining).
Slitting with Rotary Knives
Figure 16.6 Slitting with rotary knives. This process is similar to opening cans.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.