Manufacturing Processes

Sheet Metal Forming

Associate Professor Su-Jin Kim

Sheet-Metal Forming Manufacturing Processes
2011 Su-Jin Kim GNU

School of Mechanical Engineering Gyeongsang National University

Sheet metal forming ()

Sheet metal forming is a processes that shape a piece of sheet metal into the desired part through shearing() and deformation(). It is also called pressworking, press forming, or stamping.

Sheet-Metal Forming Manufacturing Processes

2011 Su-Jin Kim GNU

Contents
1. [Shearing] 2. [Forming] 3. [Press Die]

Sheet-Metal Forming Manufacturing Processes

2011 Su-Jin Kim GNU

Cutting with Shearing

()

Sheet metal is separated by applying shearing force using punch and die. Edge fracture & burr.
F
Punch
Rollover Burnish Sheet metal

Fracture
Clearance Die Burr

Sheet-Metal Forming Manufacturing Processes

2011 Su-Jin Kim GNU

Cutting with shear

1. Shearing - Separating material into two parts 2. Blanking - Removing material to use for parts 3. Punching - Removing material as scrap

Scrap Part1 Part2

Part

Part Scrap

Shearing
Sheet-Metal Forming Manufacturing Processes
2011 Su-Jin Kim GNU

Blanking

Punching

Shearing
Shearing cuts straight line to separate a piece of sheet metal into smaller parts.

Sheet-Metal Forming Manufacturing Processes

2011 Su-Jin Kim GNU

Blanking
Desired part (gears, key) is removed from sheet metal. Fine blanking, applying 3 separate forces, produces smooth and flat edges with minimal burrs and tolerances.
Punch
Stringer Upper pressure pad Sheet metal

Die
Sheet-Metal Forming Manufacturing Processes
2011 Su-Jin Kim GNU

Lower pressure cushion Blanking

Fine blanking

http://ma.gnu.ac.kr/vod/forming/Stainless_Spoon.wmv Spoon

Punching
Scrap(Hole, slot) is removed from sheet metal. Piercing - cylindrical punch Slotting - rectangular holes Perforating - large number of holes Notching - edge of sheet Lancing - partial cut to be bent Slitting - straight line Parting - separating a part Cutoff - separating a part
Sheet-Metal Forming Manufacturing Processes
2011 Su-Jin Kim GNU

Punch Force
The punch force is product of shear strength of sheet metal and cross-sectional area being sheared. Punch force : F (0.7u)tl u = ultimate tensile strength

t = thickness l = total length of the sheared edge

t l
Sheet-Metal Forming Manufacturing Processes
2011 Su-Jin Kim GNU

Ex) Calulation of punch force

Estimate the force required in punching a 25 mm diameter hole through a 1.8 mm thick 5052-O aluminium sheet at room temperature. Ultimate tensile strength of it is 190 MPa.

Solution F = (0.7 190 Mpa) (1.8 25 mm2) = 18.8 kN

Sheet-Metal Forming Manufacturing Processes

2011 Su-Jin Kim GNU

Punch press machine

Punch press

bending tool
Sheet-Metal Forming Manufacturing Processes
2011 Su-Jin Kim GNU

http://www.youtube.com/watch?v=DvONyl-ncMo AMADA
http://www.youtube.com/watch?v=vdqqm0Hi7nc LVD