Manufacturing Lecture

Manufacturing Technology I
ME 303
Chapter 20-3
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
References:
Fundamentals of Modern Manufacturing:
materials, processes, and systems, 4
th
Ed., by
Mikell P. Groover, JOHN WILEY & SONS,
INC., 2010. (Chapter 20, pages 454-461)

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

Drawing
Sheet metal forming to make cup-shaped,
box-shaped, or other complex-curved,
hollow-shaped parts
Sheet metal blank is positioned over die cavity
and then punch pushes metal into opening
Products: beverage cans, ammunition shells,
automobile body panels, sinks, and cooking
pots.
Also known as deep drawing (to distinguish it
from wire and bar drawing)
Figure 20.19 (a) Drawing
of cup-shaped part:
(1) before punch
contacts work, (2)
near end of stroke;
(b) workpart: (1)
starting blank, (2)
drawn part.
Symbols:
c = clearance,
D
b
= blank diameter,
D
p
= punch diameter,
R
d
= die corner radius,
R
p
= punch corner radius,
F = drawing force,
F
h
= holding force.

Drawing
Clearance in Drawing
Sides of punch and die separated by a
clearance c given by:
c = 1.1 t
where t = stock thickness
In other words, clearance is about 10% greater
than stock thickness
Fig 20.20 Stages in deformation of the work in deep drawing:
(1)punch makes initial contact with work, (2) bending, (3)
straightening, (4) friction and compression, and (5) final cup shape
showing effects of thinning in the cup walls. Symbols: v motion of
punch, F = punch force, F
h
= blankhold force
Mechanics of Drawing
The significant independent variables in deep drawing
are:
Properties of the sheet metal;
The ratio of the blank diameter to the punch
diameter;
The thickness of the sheet;
The clearance between the punch and the die;
The corner radii of the punch and die;
The blankholder force;
Friction and lubrication at the punch, die, and
workpiece interface;
The speed of the punch.
Depth of draw.
Tests of Drawing Feasibility
Drawing ratio
Reduction
Thickness-to-diameter ratio
Drawing Ratio DR
where D
b
= blank diameter; and D
p
= punch
diameter
Indicates severity of a given drawing operation
Upper limit: DR s 2.0
Most easily defined for cylindrical shape:
DR=
D
b
D
p
Reduction r
Defined for cylindrical shape:
r=
D
b
D
p
D
b
Value of r should be less than 0.50

Thickness-to-Diameter Ratio t/D
b
Thickness of starting blank divided by blank
diameter
Desirable for t/D
b
ratio to be greater than 1%
As t/D
b
decreases, tendency for wrinkling
increases
In case limits on drawing ratio, reduction, and
t/Db ratio are exceeded, the blank must be
drawn in two or more steps, sometimes with
annealing between the steps.

Fig 16.37 Earing a drawn steel cup, caused by
the planar anisotropy of the sheet metal
Example 20.3
A drawing operation is used to form a cylindrical
cup with inside diameter = 75 mm and height
= 50 mm. The starting blank size = 138 mm
and the stock thickness = 2.4 mm. Based on
these data, is the operation feasible?

Deep-Drawing
Figure 16.32 (a) Schematic illustration of the deep-drawing process on a circular sheet-metal
blank. The stripper ring facilitates the removal of the formed cup from the punch. (b) Process
variables in deep drawing. Except for the punch force, F, all the parameters indicated on the figure
are independent variables.

F
max
= tD
p
T UTS
( )
D
o
D
p
|
\

|
.
|
0.7

(

(
(
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Forces
The drawing force

(22.12)

The holding force
(approximately, the holding pressure = 0.015 of
the yield strength of the sheet metal )
(22.13)

where Y = yield strength of the sheet metal, MPa.
The blankholder pressure is generally 0.7% to
1.0% of the sum of the yield and the ultimate
tensile strength of the sheet metal.
|
|
.
|
\
|
0.7
p
b
p
D
D
t(TS) D = F
] ) + + (D Y[D = F
d p b h
2 2
2R 2.2t 0.015
Example 20.4
For the drawing operation of Example 20.3,
determine (a) drawing force and (b) holding
force, given that the tensile strength of the
sheet metal (low-carbon steel) = 300 MPa
and yield strength = 175 MPa. The die corner
radius = 6 mm.

Blank Size Determination
For final dimensions of drawn shape to be
correct, starting blank diameter D
b
must be
right
Solve for D
b
by setting starting sheet metal
blank volume = final product volume
To facilitate calculation, assume negligible
thinning of part wall
Other Drawing Operations
Other Drawing Operations
Fig 20.21 Redrawing of a cup: (1) start of redraw, and (2) end of stroke.
Symbols: v = punch velocity, F = applied punch force, Fh = blakholder
force.
Redrawing
When the drawing ratio is too large to form the
part in a single step, the general guide to the
amount of reduction in each drawing operation is:
for 1
st
draw, the maximum reduction of the
starting blank should be 40% to 45%;
for 2
nd
raw (1
st
redraw), the maximum reduction
should be 30%; and
for 3
rd
draw (2
nd
redraw), the maximum reduction
should be 16%.

Fig 20.22 Reverse drawing: (1) start and (2) completion.
Symbols: v = punch velocity, F = applied punch force, Fh =
blakholder force.

Fig 20.23 Drawing without a blankholder: (1) start of process, (2)
end of stroke. Symbols v and F indicate motion and applied force,
respectively
Shapes other than Cylindrical Cups
Square or rectangular boxes (as in sinks),
Stepped cups
Cones
Cups with spherical rather than flat bases
Irregular curved forms (as in automobile body
panels)

Each of these shapes presents its own unique
technical problems in drawing
Defects in Drawing
Fig 20.24 Common defects in drawn parts: (a) wrinkling can occur
either in the flange or (b) in the wall, (c) tearing, (d) earing, and (e)
surface scratches.
Other Sheet Metal Forming on Presses
Other sheet metal forming operations performed
on conventional presses
Operations performed with metal tooling
Operations performed with flexible rubber
tooling
Makes wall thickness of cylindrical cup more
uniform
Figure 20.25 Ironing to achieve more uniform wall thickness in a
drawn cup: (1) start of process; (2) during process. Note thinning
and elongation of walls.
Ironing
Creates indentations in sheet, such as raised
(or indented) lettering or strengthening ribs
Figure 20.26 Embossing: (a) cross-section of punch and die
configuration during pressing; (b) finished part with embossed ribs.
Coining and Embossing
Embossing with Two Dies
Figure 16.37 An embossing operation with two dies. Letters, numbers, and
designs on sheet-metal parts can be produced by this process.
Lancing
Fig 20.27 Lancing in several forms: (a) cutting and bending; (b) and (c)
two types of cutting and forming.
Lancing is a combined cutting and bending or cutting and
forming operation performed in one step to partially separate
the metal from the sheet.
Twisting
Twisting subjects the sheet metal to a torsion loading rather
than a bending load, thus causing a twist in the sheet over
its length.
used to make fan and propeller blades.

RUBBER FORMING PROCESSES
The operations are performed on conventional presses, but
the tooling uses a flexible element (made of rubber or
similar material) to effect the forming operation.
(1) the Guerin process, and
(2) hydroforming.

Figure 20.28 Guerin process: (1) before and (2) after. Symbols v
and F indicate motion and applied force respectively.
Guerin Process
Guerin Process
Limited to relatively shallow forms, because the
pressures developed by the rubberup to
about 10 Mpa (1500 lb/in
2
)are not sufficient
to prevent wrinkling in deeper formed parts.
Advantages:
Low tooling cost
Form block can be made of wood, plastic, or
other materials that are easy to shape
Rubber pad can be used with different form
blocks
Process attractive in small quantity production
Hydroforming
Fig 20.29 Hydroform process: (1) start-up, no fluid in cavity; (2) press closed,
cavity pressurized with hydraulic fluid; (3) punch presseinto work to form part.
Symbols: v = velocity, F = applied force, p = hydraulic pressure.
Hydroforming
Allows the pressure that forms the workpart to be
increasedto around 100 MPa (15,000
lb/in
2
)thus preventing wrinkling in deep
formed parts.
Advantages (in addition to Guerin Process):
deeper draws can be achieved compared with
conventional deep drawing.
Hydroform Process
Figure 16.40 The hydroform (or fluid-forming) process. Note that in contrast to the ordinary deep-
drawing process, the pressure in the dome forces the cup walls against the punch. The cup travels
with the punch; in this way, deep drawability is improved.
Bending and Embossing of Sheet Metal
Figure 16.39 Examples of the bending and embossing of sheet metal with a metal punch
and with a flexible pad serving as the female die. Source: Courtesy of Polyurethane
Products Corporation.
Can
Manufacture
Figure 16.31 The metal-
forming processes involved
in manufacturing a two-piece
aluminum beverage can.
Aluminum Beverage Cans
Figure 16.38 (a) Aluminum beverage cans. Note the excellent surface finish. (b)
Detail of the can lid showing integral rivet and scored edges for the pop-top.
(a)

Manufacturing Lecture

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Manufacturing Lecture

Transféré par

Droits d'auteur :

Formats disponibles

Manufacturing Technology I

Vous aimerez peut-être aussi