Manufacturing Lecture

Manufacturing Technology I
ME 303
Chapter # 20-2
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
SHEET METALWORKING
1. Cutting Operations
2. Bending Operations
3. Drawing
4. Other Sheet Metal Forming Operations
5. Dies and Presses for Sheet Metal Processes
6. Sheet Metal Operations Not Performed on
Presses
7. Bending of Tube Stock

Straining sheet-metal around a straight axis to
take a permanent bend
Figure 20.11 (a) Bending of sheet metal
Sheet Metal Bending

Metal on inside of neutral plane is
compressed, while metal on outside of neutral
plane is stretched
Figure 20.11 (b) both
compression and
tensile elongation of the
metal occur in bending.
Sheet Metal Bending
Fig 19-20 (Top) Nature of a bend in sheet metal showing tension on the
outside and compression on the inside; (bottom) upper portion of the bend
region, viewed from the side, showing how the center portion thins more
than the edges
After Materials and Processes in Manufacturing, by E. Paul DeGarmo, J.T. Black, and Ronald A. Kohser, Prentice Hall of India, 2001.
Bending produces
little or no change in
the thickness of the
sheet metal.
Types of Sheet Metal Bending
V-bending - performed with a V-shaped die
Edge bending - performed with a wiping die

Bending operations are performed using punch
and die tooling.
For low production
Performed on a press brake
V-dies are simple and inexpensive
Figure 20.12
(a) V-bending;
V-Bending
For high production
Pressure pad required
Dies are more complicated and costly
Edge Bending
Figure 20.12
(b) edge
bending.
= bend angle
R = bend radius (normally specified on the inside of the
part; determined by the radius on the tooling used)
Figure 20.11 (a) Bending of sheet metal
ENGINEERING ANALYSIS OF
BENDING

Bending Terminology
Figure 16.16 Bending terminology. Note that the bend radius is
measured to the inner surface of the bent part.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing4/e
Stretching during Bending
If bend radius is small relative to stock
thickness, metal tends to stretch during
bending
Important to estimate amount of stretching, so
final part length = specified dimension
Problem: to determine the length of neutral axis
of the part before bending
Bend Allowance Formula
where A
b
= bend allowance; = bend angle; R=
bend radius; t = stock thickness; and K
ba
is
factor to estimate stretching
If R < 2t, K
ba
= 0.33
If R 2t, K
ba
= 0.50
The values of K
ba
predict that stretching occurs only if
bend radius is small relative to sheet thickness.

t) K + (R
= A
ba b
360
2

In the ideal case where the neutral axis is at the
center of the sheets thickness, K
ba
= 0.50 and hence

where = bend angle in radians.
)] (t + [R = A
b
2 /
Bend Allowance Formula
After Materials and Processes in Manufacturing, by E. Paul DeGarmo, J.T.
Black, and Ronald A. Kohser, Prentice Hall of India, 2001.
Minimum Bend Radius
Figure 16.18 Relationship between R/T ratio and tensile reduction of area for sheet metals. Note that sheet
metal with 50% tensile reduction of area can be bent over itself in a process like the folding of a piece of paper
without cracking. Source: After J. Datsko and C. T. Yang.
Effect of Elongated Inclusions
Figure 16.17 (a) and (b) The effect of elongated inclusions stringers) on cracking as a function of
the direction of bending with respect to the original rolling direction of the sheet. (c) Cracks on the
outer surface of an aluminum strip bent to an angle of 90 degrees. Note also the narrowing of the
top surface in the bend area (due to Poisson effect).
Fig 16.17 Outer-surface cracking of an aluminum strip bent to an
angle of 90
o
. Note the narrowing of the top surface because of
Poissons effect
After Manufacturing Engineering and Technology, by S. Kalpakjian, Addison-Wesley, 1995
Springback
Increase in included angle of bent part relative to
included angle of forming tool after tool is
removed
Reason for springback:
When bending pressure is removed, elastic
energy remains in bent part, causing it to
recover partially toward its original shape
Figure 20.13 Springback in bending is seen as a decrease in bend angle
and an increase in bend radius: (1) during bending, the work is forced
to take radius R
b
and included angle
b
' of the bending tool, (2) after
punch is removed, the work springs back to radius R and angle .
Springback

Springback in Bending
Figure 16.19 Springback in bending. The part tends to recover elastically after bending, and its bend radius
becomes larger. Under certain conditions, it is possible for the final bend angle to be smaller than the original
angle (negative springback).
SB=
'
t
'
t
'
(22.7)
where
SB = springback;
' = included angle of the sheet-metal part, degrees; and
'
t
= included angle of the bending tool, degrees.
The amount of springback increases with modulus of elasticity and
yield strength of the work metal.

Springback

Compensation for springback:
Overbending: the punch angle and radius are
fabricated slightly smaller than the specified angle so
that the sheet metal springs back to the desired
value.
Bottoming: To coin the bend area by subjecting it to
high localized compressive stresses between the tip
of the punch and the die surface, thus plastically
deforming it in the bend region.
Stretch bending: in which the part is subjected to
tension while being bent.
Figure 19-27 Comparison of air-bend (left) and bottoming (right)
press brake dies.
After Materials and Processes in Manufacturing, by E. Paul DeGarmo, J.T. Black, and Ronald A. Kohser, Prentice Hall of India, 2001.
Methods of Reducing or Eliminating
Springback
Figure 16.20 Methods of reducing or eliminating springback in bending operations.
Source: After V. Cupka, T. Nakagawa, and H. Tyamoto.
Bending Force
depends on the geometry of the punch-and-die
and the strength, thickness, and length of the
sheet metal.
Maximum bending force estimated as follows:
where F = bending force; TS = tensile
strength of sheet metal; w = part width in
direction of bend axis; t = stock thickness;
and D = die opening dimension. For V-
bending, K
bf
= 1.33; for edge bending, K
bf
=
0.33
F=
K
bf
TSwt
2
D
Figure 20.14 Die opening dimension D: (a) V-die, (b) wiping die.
Die Opening Dimension
Common Die-Bending Operations
Figure 16.21 Common die-bending operations showing the die-
opening dimension, W, used in calculating bending forces.
Bending Force
Example 20.2
A sheet-metal blank is to be bent as shown in
Figure 20.15. The metal has a modulus of
elasticity = 205 (103) MPa, yield strength = 275
MPa, and tensile strength = 450 Mpa. Determine
(a) the starting blank size and (b) the bending
force if a V-die is used with a die opening
dimension = 25 mm.

OTHER BENDING AND FORMING
OPERATIONS
Flanging: is a bending operation in which the
edge of a sheet-metal part is bent at a 90
o

angle (usually) to form a rim or flange.
used to strengthen or stiffen sheet metal.
The flange can be formed over a straight bend
axis (a), or it can involve some stretching (b) or
shrinking (c) of the metal.

Flanging Operations
Figure 16.25 Various flanging
operations. (a) Flanges on a
flat sheet. (b) Dimpling. (c)
The piercing of sheet metal to
form a flange. In this operation,
a hole does not have to be pre-
punched before the punch
descends. Note, however, the
rough edges along the
circumference of the flange.
(d) The flanging of a tube.
Note the thinning of the edges
of the flange.
OPERATIONS
Hemming: involves bending the edge of the
sheet over on itself.
Often done to
eliminate the sharp edge on the piece,
to increase stiffness, and
to improve appearance.

OPERATIONS
Seaming: is an operation in which two sheet-
metal edges are assembled.

OPERATIONS
Curling (beading): forms the edges of the part
into a roll or curl,
it is done for
purposes of safety,
strength, and
aesthetics. Examples

Bead Forming
Figure 16.24 (a) Bead forming with a single die. (b) and (c) Bead forming with two
dies in a press brake.
Fig 20.18 Miscellaneous bending operations: (a) channel bending,
(b) U-bending, (c) air bending, (d) offset bending, (e) corrugating,
and (f) tube forming. Symbol F = applied force
Bending Operations
Figure 16.22 Examples of various bending operations.

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Manufacturing Technology I

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