ENM 208
SHEET METAL WORKING
ANADOLU UNIVERSITY
Industrial Engineering Dep.
Saleh AMAITIK
Manufacturing Processes
Sheet Metalworking
Sheet metalworking includes Cutting and Forming
operations performed on relatively thin sheets of metal.
Most sheet metal thicknesses are between 0.4 mm and 6
mm.
When thickness exceeds about 6 mm, the stock is
usually referenced to as plate rather than sheet.
Operations usually performed as cold working.
Sheet and plate metal parts for consumer and industrial products
such as
- Automobiles and trucks
- Farm and construction equipment
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- Office furniture
- Airplanes
Manufacturing Processes
Advantages of Sheet Metal Parts
• High strength
• Good dimensional accuracy
• Good surface finish
• Relatively low cost
• For large quantities, economical mass production
operations are available
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Manufacturing Processes
Categories of Sheet Metalworking Processes
The three major categories of sheet metal processes are:
• Cutting
– Shearing to separate large sheets; or cut
part perimeters or make holes in sheets
• Bending
– Straining sheet around a straight axis
• Drawing
– Forming of sheet into convex or concave
shapes
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Manufacturing Processes
Sheet Metalworking Terminology
The tooling used to perform sheet metalwork is called
Punch and Die.
Most sheet metal operations are performed on machine
tools called Presses.
The term Stamping Press is used to distinguish these
presses from forging and extrusion presses.
The sheet metal products are called Stampings.
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Manufacturing Processes
Cutting Operations
Cutting of sheet metal is accomplished by a shearing action
between two sharp cutting edges.
(1) just before the punch contacts work
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(2) punch begins to push into work,
causing plastic deformation
Manufacturing Processes
Cutting Operations
(3) punch compresses and penetrates
into work causing a smooth cut surface
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(4) fracture is initiated at the
opposing cutting edges which
separates the sheet
Manufacturing Processes
Shearing, Blanking, and Punching
There are three principal operations in pressworking that cut metal
by shearing mechanism:
• Shearing
• Blanking
• Punching
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Manufacturing Processes
Shearing Operation
Shearing is a sheet metal cutting operation along a
straight line between two cutting edges.
(a) side view of the shearing operation
(b) front view of power shears equipped with inclined upper cutting blade
Symbol v indicates motion
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Manufacturing Processes
Blanking Operation
Blanking involves cutting of the sheet metal along a
closed outline in a single step to separate the piece
from the surrounding stock.
The part that is cut out is the desired product in the operation and
is called the blank.
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Manufacturing Processes
Punching Operation
Punching is very similar to blanking except that the
piece that is cut is scrap, called the slug.
The remaining stock is the desired part.
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Manufacturing Processes
Analysis of Sheet-Metal Cutting
Clearance c
Distance between
punch and die.
the
Typical
values
range
between 4% and 8% of
stock thickness.
Recommended clearance
can be calculated by:
c = at
where
c = clearance;
a = allowance; and
t = stock thickness
- Allowance a is determined
according to type of metal
Die size determines blank size Db;
Punch size determines hole size Dh.;
c = clearance
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Manufacturing Processes
Analysis of Sheet-Metal Cutting
Allowance a for Three Sheet Metal Groups
Metal group
a
Aluminum alloys
0.045
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
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Manufacturing Processes
Analysis of Sheet-Metal Cutting
Punch and Die Sizes for Blanking and Punching
• For a round blank of diameter Db:
– Blanking punch diameter = Db - 2c
– Blanking die diameter = Db
– where c = clearance
• For a round hole of diameter Dh:
– Hole punch diameter = Dh
– Hole die diameter = Dh + 2c
– where c = clearance
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Manufacturing Processes
Analysis of Sheet-Metal Cutting
Cutting Forces
Estimates of cutting force are important because this
force determines the size of thee press needed. Cutting
force in sheet metalworking can be determined by
F=StL
where
S = shear strength of metal (MPa);
t = stock thickness (mm), and
L = length of cut edge (mm)
In blanking and punching operations, L is the perimeter length of
the blank or hole being cut.
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Manufacturing Processes
Bending Operations
Bending in sheet-metal work is defined as the training
of the metal around a straight axis (a).
During the bending operation, the metal on the inside of the
neutral plane is compressed, while the metal on the outside of the
neutral plane is stretched (b).
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Manufacturing Processes
Types of Bending Operations
V-bending
performed with a V-shaped die
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Edge bending
performed with a wiping die
Manufacturing Processes
Drawing
Drawing is a 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
(a) Drawing of a cup-shaped part:
(1) start of operation before punch
(2) contacts work near end of stroke
(b) Corresponding workpart:
(1) starting blank
(2) drawn part
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