Sheet Metal Presswork

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 Different types of presses

C-Frame Mechanical Press H-Frame Hydraulic Press

 Types of press tools

Simple tool Compound tool

Progressive tools stages

Cutting Operation Observations
F = S t L, where S = shear strength of metal; t = stock thickness, and L = perimeter length of blank or hole being cut.
In a typical rolling, the thickness of a metal plate is reduced by two rotating mills. The
starting work material in rolling is a metal plate. On the other hand, sheet metalworking
operations are performed on relatively thin metal sheets.

Examples:

It is required to produce 50 mm diameter blanks from 2 mm thick low-carbon steel.

If a clearance allowance of 6% is chosen, then
diameter of die = diameter of blank = 50 mm, Dpunch = Dblank - 2c
clearance per side, c=at, = 6% of 2 mm = 0.12 mm
clearance on diameter is, therefore, 2 × 0.12 mm = 0.24 mm
Thus, the diameter of the punch is smaller than the die by this amount; therefore, the
diameter of the punch = 50 mm − 0.24 mm = 49.76 mm

Punching 20 mm diameter holes in 1.5 mm thick copper is required. If a clearance

allowance of 4% is chosen, then the diameter of punch = diameter of hole = 20 mm
Dhole=Dpunch+2c,
clearance per side, c=at, = 4% of 1.5 mm = 0.06 mm,
clearance on diameter is therefore 2 x 0.06 mm = 0.12 mm
Thus, the diameter of the die is larger than the punch by this amount; therefore, the
diameter of the die = 20 mm + 0.12 mm = 20.12 mm
c = a*t
where c = clearance; a = clearance allowance; and t = stock thickness
• Allowance a is determined according to the type of metal
Blanking – Punching- Exercise

A blanking die is designed to blank the part outline in the

figure below. The material is 4 mm thick stainless steel
(the allowance for the stainless steel is a = 0.075).
Determine the dimensions of the blanking punch and the
die opening.

Solution:

Since a = 0.075, the clearance is given by,

c = a*t = 0.075 (4) = 0.3 mm.

Blanking die dimensions: the same as for the part in the figure:
L = 85 mm w = 50 mm t = 25 mm s = 25 mm

Blanking punch dimensions:

Blanking Punch = Db -2c
Length L = 85 - 2(0.3) = 84.4 mm
Width w = 50 - 2(0.3) = 49.4 mm
Top and bottom t widths = 25 - 2(0.3) = 24.4 mm
The s1 = 25- 2(0.3) = 24.4 mm
The s2 = 35 – 2 (0.3) = 34.4mm
Die opening dimensions:
Use the formula Dhole=Dpunch+2c to finish this work.
A compound die will blank and punch a large washer out of 6061ST aluminium alloy (the allowance is a = 0.06), sheet stock
3.50 mm thick. The washer’s outside diameter is 50 mm, and the inside diameter is 15 mm. Determine (a) the punch and
die sizes for the blanking operation and (b) the punch and die sizes for the punching operation.

Solution:

Since a = 0.06, the clearance is given by,

c =a*t = 0.06 (3.5) = 0.21 mm

(a) Blanking punch diameter = Db + 2c = 50 + 2(0.21) = 50.42 mm

Blanking die diameter = Db = 50 mm

(b) Punching punch diameter = Dh = 15 mm

Punching die diameter = Dh + 2c = 15 - 2(0.21) = 14.58 mm
A blanking operation will be performed on 2 mm thick cold rolled steel. The part is
circular with diameter = 75 mm.
Determine: a) the appropriate punch and die sizes for this operation if the
allowance for the cold rolled steel is a = 0.075. b) the blanking force required if the
steel has a shear strength = 325 MPa and the tensile strength is 450 MPa

Solution:

(a) Since a = 0.075, the clearance is given by,

c = a*t = 0.075 (2) = 0.15 mm.

Thus, the Punch diameter Dh is calculated as

Dh = Db - 2c = 75.0 - 2(0.15) = 74.70 mm. And the Die diameter is Db = 75 mm.

(b) the blanking force is given by

F = StL

The thickness of the metal stock t is given by the problem as t = 2 mm

The length of the cut edge is calculated as:

L = πD = 75π = 75π mm

Thus, the blanking force is

F = 325 (2) (75π) = 153.153 kN

F=0.7Ts.tL

F= 0.7*450*2*75π

F= 148.440 kN

F = StL ≈ 0.7Ts.tL
The multi-purpose bottle opener, shown in Figure below, was manufactured using the Sangiacomo 63-ton press at the CPUT
engineering workshop. The 304L stainless steel inspection certificate showed a shear strength of 450 MPa and an ultimate
tensile strength of 576 MPa. The front window has a base of 20.36 mm, a height of 6.36 mm, and a length of 22.93 mm.
The rear window has a base of 14.03 mm, a height of 5.50 mm, and a length of 14.16 mm. The total length of the artifact is
250 mm, and the ring hole has a diameter of 3.970 mm and a thickness of 1.5 mm.
Calculate:
(a) the punching tonnage (use shear stress in your calculations), the Sangiacomo 63-ton press used, and (12)
(b) the blanking tonnage (use ultimate tensile stress in your calculations); the Sangiacomo 63-ton press used
(3)

Multi-purpose bottle opener

Hint:
𝐶 = 𝑎𝑡

𝐹 = 𝑆𝑡𝑙 ≅ 0.7𝑇𝑠 𝑡𝑙
Deep Drawing feasibility
 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟𝑏𝑙𝑎𝑛𝑘
𝐷𝑟𝑎𝑤𝑖𝑛𝑔𝑅𝑎𝑡𝑖𝑜 =
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟𝑝𝑢𝑛𝑐ℎ
𝐷𝑏
𝐷𝑅 = ≤ 2 equation 1 (less/equal)
𝐷𝑝

𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟𝑏𝑙𝑎𝑛𝑘 − 𝐷𝑎𝑖𝑚𝑒𝑡𝑒𝑟𝑝𝑢𝑛𝑐ℎ
𝑅𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛 =
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟𝑏𝑙𝑎𝑛𝑘
𝐷𝑏 −𝐷𝑝
𝑅= ≤ 50% equation 2 (less/equal)
𝐷𝑏
𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠
𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑡𝑜 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑟𝑎𝑡𝑖𝑜 =
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟𝑏𝑙𝑎𝑛𝑘
𝑡
𝑡𝐷𝑟 = ≥ 1% equation 3 (greater/equal)
𝐷𝑏
Deep drawing
A cup is to be drawn in a deep drawing operation. The height of the cup
is 75 mm, and its inside diameter = 100 mm. The sheet metal thickness
= 2 mm. If the blank diameter = 225 mm, determine (a) drawing ratio,
(b) reduction, and (c) thickness-to-diameter ratio. (d) Does the operation
seem feasible?
(e) for the previous operation, determine (i) drawing force and (ii) holding force, given that
the tensile of the sheet metal (low-carbon steel)
= 300MPa and yield strength = 175 MPa. The die corner radius = 6 mm.
𝐷𝑏 225
(i) 𝐹 = 𝜋𝐷𝑝 𝑡𝑇𝑠 ൬ − 0.7൰ = 𝜋ሺ100ሻሺ2ሻሺ300ሻ ቀ − 0.7ቁ = 𝟐𝟗𝟐, 𝟏𝟔𝟖𝒌𝑵
𝐷𝑝 100
(ii) 𝐹ℎ = 0.015𝑌𝜋൛𝐷𝑏2 − ሺ𝐷𝑝 + 2.2𝑡 + 2𝑅𝑑 ሻ2 ൟ
= 0.015ሺ175ሻ𝜋ሼ2252 − [100 + 2.2ሺ2ሻ + 2ሺ6ሻ]2 ሽ
= 8.25ሼ50625 − [13548.96]ሽ
= 𝟑𝟎𝟓, 𝟖𝟕𝟕𝒌𝑵
Press Brake Bending

• Form sheet into a variety of shapes.

• RAM, which moves vertically to press against the bed.
• Punches are bolted onto RAM and they match die fastened to bed.
• P.B. can be mechanically or hydraulically operated.
• Die sets are inexpensive - today 'urethane' is used as male (die) half - accuracy and repeatability is excellent.

Two common bending methods are V-bending and edge-bending.

Bending Allowance:

The sheet metal of thickness (t) is bent through a bend angle A. This results in a sheet metal part with an included angle A’, where A + A’ =
180°. The bend is made over the width (w) of the workpiece. The length of the neutral axis needs to be determined to account for stretching
of the final bend. This length is called the bend allowance and is estimated as follows:
Spring-back:

When the bending pressure is removed

at the end of the deformation operation,
elastic energy remains in the bent part,
causing it to recover partially toward its
original shape. This elastic recovery is
called spring back, defined as the
increase in the included angle of the bent
part relative to the included angle of the
forming tool after the tool is removed.

Tube Bending:
• Round tubing used for fuel lines, plumbing supplies, cooling and heating coils and car muffler requires bending.
• Both square and round tubing used for furniture may require bending.
• To form/bend this material, special tube-bending machines are available.
• N.C. tube-benders will, at command of the
punched tape, measure to length, bend to proper
angle, rotate the part if necessary, clamp,
measure and make the next bend and cut off
automatically.
Materials suitable for drawing:
• Low carbon steel
• Aluminium
• Copper Alloy
• Stainless steels

Lubrication:
• Lubricants or drawing compounds are used to reduce friction forces.
• Lubrication is necessary as sliding friction is great and pressure welding (galling) may occur.
• Lubricant may be brushed /sprayed on or sheets may be pre-lubricated.
• Lubricants used:

Oil, soap solution, grease, wax, moly disulfide and water – soluble oil
The tooling in the Guerin Process is made of a thick rubber pad, which is confined in a steel container.
As the ram descends, the rubber gradually surrounds the sheet, applying pressure to deform it to the
shape of the form block. The form block can be made of wood, plastics, or other materials that are easy
to shape. This type of tooling is relatively low-cost.
Sheet Metal Products
Sheet metal parts for consumer and industrial • Economical mass production for large
products, such as quantities
– Automobiles and trucks
– Airplanes
– Railway cars and locomotives
– Farm and construction equipment
– Small and large appliances
– Office furniture
– Computers and office equipment

Advantages of Sheet Metal Parts

• High strength
• Good dimensional accuracy
• Good surface finish
• Relatively low cost
Homework:

Check the textbook written by: Groover, M.P. 2011. Principles of Modern Manufacturing, Fifth edition. John Wiley & Sons Singapore Pte. Ltd.
Library Shelf No.: BEL670.42 GRO. ISBN 978-1-118-47420-4:

1. Do the following examples 16.1; 16.3; 16.4.

2. Do the following problems 16.1 – 16.6.
3. Do the following problems 16.14 – 16.20.