PRESS WORKING OPERATIONS(SHEET METAL)

P R E S S W O R K I N G O P E R A T I O N S
( S H E E T M E T A L )

C U T T I N G B E N D I N G F O R M I N G D R A W I N G

B L A N K I N G B E N D I N G S T R E T C H F L CA YN LG I NI N D G R I C A L
C U P
D R A W I N G

P I E R C I N G F L A N G I N GS H R I N K F L A R N E G C I NT AG N G U L A R
S H E L L
D R A W I N G

N O T C H I N G H E M M I N GR E V E R S E F L IA R N R G E I GN UG L A R
S H A P E
D R A W I N G

T R I M M I N G H O L E F L A N G I N G

L A N C I N G E m b o s s i n g /
F o r m B e a d s

J O G G L E
 THEORY OF CUTTING

When cutting sheet metal in a die the forces applied to

the sheet by the punch and die are basically shear
forces, that is, equal and opposite forces spaced at a
small distance apart on the metal and produce the
cutting.
The cutting or separation of the sheet metal is effected
through the following stages of shearing
• Roll over
• Penetration
• Fracture
From both punch side and Die side simultaneously
The spacing or the small distance of the two shearing
planes is called clearance.It will be generally about
8 - 10% of metal thickness for MS Sheets.
SHEET METAL CUTTING TERMINOLOGY
 VARIOUS CUTTING OPERATIONS
BLANKING It is the operation of cutting
or shearing a piece out of
sheet to a predetermined
contour

PIERCING It is the operation of

producing the holes of round
or contoured shape in the
blanks or in formed parts.

NOTCHING In Notching operation a small

piece or pieces of metal are
removed from the edges/
corners of a Strip or a Blank
TRIMMING It is the operation of cutting
off the excess metal after the
Drawing or Forming
operation

LANCING It is the operation of slitting

on three sides and opening
out by bending the lug about
an axis on the uncut fourth
side with in the blank.
 THEORY OF BENDING AND SPRING BACK
• BENDING
Bending is the process of folding a sheet about a straight line axis
which lies in the neutral plane.
Bends are made in sheet metal to gain rigidity, to produce a part of
desired shape & perform a particular function etc. The cross
section of the bend inward from neutral axis is in compression,
outward from neutral axis is in tension as shown in the fig.
• SPRING BACK
During bending the metal nearer to the neutral axis is stressed to the
values below the elastic limit.This phenomenon creates a narrow
elastic band on both sides of the neutral axis.The metal further
away from the neutral axis is stressed beyond the yield strength
and is plastically deformed and permanently set. When the
bending force on the metal is released the elastic band tries to
return to the original flat condition but cannot return fully due to
the restrictions of the plastically deformed zones . Some slight
return does occur as the elastic and plastic zones come to an
equilibrium and this return is known as spring back.
• The amount of spring back mainly depends on the ratio of bending
radius to stock thickness.
• Spring back can be reduced by over bending, Bottoming or stretch
bending.
 VARIOUS BENDING OPERATIONS
SIMLPE The operation of Folding the sheet about a
BENDING straight-line axis is called simple bending

FLANGING It is similar to above in which the height of

bend is shorter compared to the overall size
of the part.
• It strengthens the edges of sheet metal
parts
• It provides flanges required for
assembling parts by spot welding or any
other joining processes.

HEMMING Hemming is an operation in which the edge

0
of a component gets folded by180 .
• It improves the rigidity of the edge
• It facilitates joining of two parts as in the
case of Bonnetassy. /Doorassy.
 DESIGN CONSIDERATIONS FOR BENDING
Radius of bend ≥
T
Minimum height of bend ≥
3T

Relief Notches for bend

 DESIGN CONSIDERATIONS FOR HEMMING
Where appropriate provide an offset
• To minimise area of fitting
• To give additional rigidity to inner
panel
• To reduce potential assembly distortion

•
Height of flange after
0 +/- 1.0
90 flanging = 9.0
( except at corners and feature lines)

•Maximum permissible radius of bend

0
during 90 flanging = 0.5T
•Preferred radius of bend during 90
0

flanging = 0 (or as minimum as

possible)
 THEORY OF FORMING
• Forming is the process in which the
shape of the punch and die is directly
reproduced in the metal with little or no
metal flow.
• Forming, Bending or drawing actions
may be combined in a die and is
classified as Form die or Draw die
depending on the dominant action of
process
• The decision to use a form die instead
of a Draw die will depend largely on
the complexity of the shape &
geometrical criteria.
• The use of draw die may be indicated,
if the form die would cause the metal to
tear because of excessive tensile
strain(stretch) or form objectionable
wrinkles because of excess crowding
of metal etc defects.
VARIOUS TYPES OF FORMING OPERATIONS
VARIOUS TYPES OF BEADS
 DESIGN CONSIDERATIONS FOR BEADS

ANGULAR
BEADS

V-BEADS

BEAKS
 THEORY OF DRAWING
• Drawing is a process in which the punch causes a flat , precut metal blank in to the die cavity to
assume the shape of seamless hollow vessel without excessive wrinkling, thinning, or fracturing.
• METAL FLOW IN DRAWING PROCESS
when the punch of draw die forces a portion of metal blank through the bore of draw ring, different
forces such as radial tension, circumfrential compression and bending & frictional forces come in to
action as shown in the fig.These forces cause a complicated plastic flow of the material in the blank.
The volume and the thickness of the component remain constant and the final shape of the cup will be
similar to contour of the punch.
The progressive stages of cupping are schematically shown in fig. After a small stroke of the punch,
cupping stage A, the metal elements 2, 3, 4, & 5 of the blank move radially toward the center of the
blank. The flow of these elements go on till the final stage C of the cup is reached. Thus by the end of
the draw of the cup area 1 is unchanged in shape and size in the bottom of the cup. The areas 2,3 & 4
change from the shape of angular segments to longer parallel-sided shapes and area 5 also changed in
it’s size and shape.
Due to this metal flow phenomena in Drawing operation, Blank holding pressure is to be applied on
the blank in such a way that the metal flow will be a controlled one so as to avoid wrinkling, tearing,
thinning etc.
DESIGN CONSIDERATIONS FOR CYLINDRICAL CUP DRAWING
• Empirical Rule to decide required
no. of Draws for Cylindrical cup
(Where h = inside height of shell
d = Mean dia. Of shell)
• Drawing Force for Cylindrical Cup
(Fd)
• Blank Holder Force( Fb)
• Empirical Rule for Punch and Die
radii.
If λ =h/d No. of Draws
Up to 0.75 --------- 1
0.75 -- 1.5 --------- 2
1.5 -- 3.0 --------- 3
3.0 -- 4.5 --------- 4
Fd = Π d t (S u + Sy)/2 Kg.
Where d = Punch diameter (mm.)
2
Su = Ultimate Tensile strength (Kg/mm )
2
Sy = Yield strength (Kg/mm )
T = Thickness of sheet. (mm.)
Fb = 1/3 of Drawing force(Approx.)
Punch Radius = 5t
Die radius = 6t
 DESIGN CONSIDERATIONS FOR RECTANGULAR SHELL DRAWING
• Empirical Formulae to decide If λ =h/r No. of Draws
required no. of Draws for Up to 7 --------- 1
Rectangular shell 7 -- 13 --------- 2
(Where h = inside height shell 13 -- 18 --------- 3
r = Corner radius Of shell) 18 -- 24 --------- 4

• Drawing Force Rectangular Shell Fr = t Su (2Πr + C1+L C2 ) Kg.

(Fr)
Where
2
Su = Ultimate Tensile strength (Kg/mm )
T = Thickness of sheet. (mm.)
r = Corner radius Of shell. (mm.)
L = Total length of straight sides of
rectangular shell
C1 = 0.5 – 2(lower values for shallow draw
Higher values for h/r > 0
C2 = 0.2 – 0.3 ( For easy to sever Draw
Conditions)
 DESIGN CONSIDERATIONS FOR IRREGULAR SHAPE DRAWING
• Empirical Formulae to If e% < 5 , Part can be produced
analyze the formability by Forming
of Irregular shaped If 5 < e% < 30 , Part requires Draw
shells If e% > 30 , Part cannot be formed
If ∆e% > 5 Wrinkles tend to be shown

Where e% = Percentage of elongation

= (L – L 0) x 100
L0 = Blank length before forming
L = Blank length after forming
∆e% = Difference in percentage of
elongation between neighboring
sections
• General guide lines • Draft angle on draw panel wall = 2 0 Min.
related to Drawing • Maximum permissible material thinning = 10%
Operation • Material utilization Target = 70% and above
• Drawn corners to be achieved in one Draw