‭Experiment no.

4‬

‭Sheet Metal Operations‬

‭Objective:‬

‭1.‬ ‭To‬‭understand‬‭the‬‭sheet‬‭metal‬‭working‬‭in‬‭general‬‭with‬‭a‬‭proper‬‭understanding‬‭of‬‭the‬
‭mechanisms of shearing and bending operations.‬

2‭ .‬ ‭To‬‭calculate‬‭the‬‭cutting‬‭forces‬‭as‬‭well‬‭as‬‭understanding‬‭the‬‭defects‬‭during‬‭the‬‭shearing‬
‭and bending operations.‬

‭Machine and materials used:‬

‭Sheet metal, tool, punch, die etc‬‭.‬

‭Introduction‬‭:‬
‭ heet‬ ‭metal‬ ‭operation‬‭is‬‭defined‬‭as‬‭a‬‭chip-less‬‭manufacturing‬‭process‬‭by‬‭which‬‭various‬‭components‬
S
‭are‬ ‭made‬ ‭from‬ ‭sheet‬ ‭metal‬ ‭.‬ ‭The‬ ‭process‬ ‭of‬ ‭obtaining‬ ‭a‬ ‭desired‬ ‭shape‬ ‭out‬‭of‬‭a‬‭metal‬‭sheet‬‭using‬‭a‬
‭punch‬‭and‬‭die‬‭is‬‭termed‬‭as‬‭sheet‬‭metal‬‭operation.‬‭A‬‭sheet‬‭of‬‭a‬‭metal‬‭is‬‭roughly‬‭defined‬‭to‬‭be‬‭having‬‭a‬
‭thickness‬‭up‬‭to‬‭6‬‭mm.‬‭The‬‭process‬‭is‬‭generally‬‭performed‬‭at‬‭a‬‭temperature‬‭below‬‭its‬‭recrystallisation,‬
‭which‬ ‭makes‬ ‭it‬ ‭a‬ ‭cold‬ ‭working‬ ‭process.‬ ‭The‬ ‭process‬ ‭is‬ ‭widely‬ ‭used‬ ‭in‬ ‭making‬ ‭utensils,‬ ‭parts‬ ‭in‬
‭automobiles‬‭as‬‭well‬‭as‬‭in‬‭the‬‭aerospace‬‭industry.‬‭Most‬‭of‬‭the‬‭metal‬‭casings‬‭of‬‭different‬‭appliances‬‭are‬
‭made out of these sheet metal processes.‬

‭Fig.1: shearing and bending operations on the inner panel of automobile door‬
 ‭Fig.2: shearing and bending operations on the fuselage and wing of aircraft‬

‭Sheet metal operations‬‭:‬

‭Sheet metal operations may be grouped into following two categories:‬

1‭ )‬ ‭Cutting‬ ‭Operations:‬ ‭In‬ ‭these‬ ‭operations‬ ‭the‬ ‭work‬ ‭piece‬ ‭is‬ ‭stressed‬ ‭beyond‬ ‭its‬ ‭ultimate‬
‭strength‬‭and‬‭the‬‭fracture‬‭is‬‭caused‬‭by‬‭the‬‭shearing‬‭stresses‬‭induced‬‭in‬‭the‬‭metal‬‭by‬‭the‬‭applied‬
‭forces.‬ ‭We‬ ‭will‬ ‭discuss‬ ‭the‬ ‭shear‬ ‭cutting‬ ‭operation‬ ‭in‬ ‭detail‬ ‭which‬ ‭is‬ ‭one‬ ‭of‬ ‭the‬ ‭cutting‬
‭operations.‬

2‭ )‬‭Forming‬‭Operations:‬‭In‬‭these‬‭operations‬‭the‬‭stresses‬‭are‬‭below‬‭the‬‭ultimate‬‭strength‬‭of‬‭the‬
‭metal.‬‭There‬‭is‬‭no‬‭cutting‬‭of‬‭the‬‭metal‬‭but‬‭the‬‭shape‬‭of‬‭the‬‭work‬‭piece‬‭is‬‭changed‬‭to‬‭get‬‭the‬
‭desired‬‭product.‬‭We‬‭will‬‭discuss‬‭the‬‭bending‬‭operation‬‭in‬‭detail‬‭which‬‭is‬‭one‬‭of‬‭the‬‭forming‬
‭operations.‬
‭Shearing /shear cutting :‬
‭ he‬‭shear‬‭cutting‬‭processes‬‭are‬‭part‬‭of‬‭the‬‭separation‬‭manufacturing‬‭processes,‬‭standardized‬
T
‭in‬‭(DIN‬‭8580‬‭2003)‬‭and‬‭more‬‭precisely‬‭characterized‬‭in‬‭(DIN‬‭8588‬‭2013)‬‭as‬‭the‬‭mechanical‬
‭separation‬ ‭of‬ ‭workpieces‬ ‭without‬ ‭forming‬‭shapeless‬‭matter.‬‭Here,‬‭shapeless‬‭matter‬‭refers‬‭to‬
‭chips or grinding dust, for example.‬

‭Mechanism of shearing‬

‭ he‬ ‭mechanism‬ ‭of‬ ‭the‬ ‭shear‬ ‭cutting‬ ‭operation‬ ‭is‬ ‭comprehensively‬ ‭explained‬ ‭in‬ ‭the‬
T
‭Figure.2‬ ‭where‬ ‭F‬‭NH‬ ‭is‬ ‭the‬ ‭blank‬ ‭holding‬ ‭force‬ ‭and‬ ‭F‬‭S‬ ‭is‬ ‭the‬ ‭cutting‬ ‭force.‬ ‭the‬ ‭shearing‬
‭operation can be divided into the following five different phases.‬

‭Phase 1: The punching tool comes into contact with the sheet metal plate.‬

‭ hase‬‭2:‬‭The‬‭movement‬‭of‬‭the‬‭punching‬‭tool‬‭introduces‬‭compressive‬‭stress‬‭into‬‭the‬‭sheet‬
P
‭metal.‬ ‭This‬ ‭stress‬ ‭is‬ ‭transmitted‬ ‭through‬ ‭the‬ ‭material‬ ‭and‬ ‭into‬ ‭the‬ ‭matrix.‬ ‭The‬
‭compressive stress leads to elastic deformation of the sheet metal plate.‬

‭ hase‬ ‭3:‬ ‭The‬ ‭compressive‬ ‭stress‬ ‭exceeds‬ ‭the‬ ‭yield‬ ‭strength‬ ‭of‬ ‭the‬ ‭workpiece‬ ‭material,‬
P
‭causing‬ ‭plastic‬ ‭deformation‬ ‭of‬‭the‬‭sheet‬‭metal‬‭plate.‬‭This‬‭leads‬‭to‬‭edge‬‭warping‬‭and‬‭the‬
‭clear-cut surface.‬

‭ hase‬‭4:‬‭The‬‭breaking‬‭limit‬‭of‬‭the‬‭workpiece‬‭material‬‭is‬‭exceeded,‬‭leading‬‭to‬‭the‬‭fracture‬
P
‭phase. Crack formation begins at the edge of the punching matrix.‬

‭ hase‬‭5:‬‭After‬‭separation‬‭from‬‭the‬‭punched‬‭area,‬‭elastic‬‭stress‬‭is‬‭released,‬‭causing‬‭elastic‬
P
‭vibrations in the workpiece.‬
 ‭Fig.3 : Phases of the shear cutting process with a typical cutting force – punch travel‬
‭graph with corresponding phases‬

‭ uring‬ ‭shearing,‬ ‭material‬ ‭initially‬ ‭deforms‬ ‭plastically‬ ‭in‬ ‭a very‬ ‭small‬ ‭region‬ ‭Rollover‬
D
‭depth (h‬‭E‭)‬ ‬‭,‬ ‭causing‬ ‭a‬ ‭residual‬ ‭deformation.‬ ‭Afterwards,‬ ‭the‬ ‭upper‬ ‭blade‬ ‭penetrates‬ ‭the‬
‭material‬ ‭forming‬ ‭a clean‬ ‭zone‬ ‭Burnishing‬ ‭depth (h‬‭S‭)‬ ‬‭where‬ ‭cutting‬ ‭is‬‭neat‬‭and‬‭regular.‬
‭Close‬ ‭to‬ ‭the‬ ‭end‬ ‭of‬ ‭the‬ ‭shearing,‬ ‭material‬ ‭gives‬ ‭in‬ ‭and‬ ‭cracks,‬ ‭producing‬ ‭a‬ ‭rough‬ ‭and‬
‭irregular‬ ‭surface‬ ‭known‬ ‭as‬ ‭the fractured‬ ‭zone‬ ‭fracture‬ ‭depth‬ ‭(h‬‭B‬‭)‭,‬‬ ‭which‬ ‭extends‬ ‭into‬
‭the edge‬‭burr‬‭Burr‬‭height (h‬‭G‭)‬ ‬‭.‬‭Fractured‬‭zone‬‭is‬‭often‬‭not‬‭perpendicular‬‭to‬‭the‬‭plate‬‭but‬
‭at‬ ‭an‬ ‭angle.‬ ‭A‬ ‭typical‬ ‭cutting‬ ‭operation‬ ‭produces‬ ‭rollover,‬ ‭burnish,‬ ‭fractured‬ ‭zone‬ ‭and‬
‭burr as shown in figure 3.‬
 ‭Fig.4 : A typical sheared edge of the workpiece‬

‭Calculation of cutting forces:‬

‭ he‬ ‭estimation‬ ‭of‬ ‭the‬ ‭cutting‬ ‭force‬ ‭helps‬ ‭in‬ ‭determining‬ ‭the‬ ‭press‬ ‭size.‬ ‭Cutting‬ ‭force‬ ‭F‬ ‭in‬
T
‭sheet metal working can be calculated as:‬

‭F = StL‬

‭Where, S = shear strength of metal, MPa; t = stock or sheet thickness, mm; L = length of‬
‭cutting edge, mm. If the shear strength is unknown, an alternative way of estimating the‬
‭cutting force is to use the tensile strength:‬

‭F = 0.7(TS)tL‬

‭TS = ultimate tensile strength, MPa.‬

‭Defects:‬

‭1.‬ B ‭ owing:‬ ‭The‬ ‭sheet‬ ‭metal‬ ‭is ‭n ‬ o longer‬ ‭flat‬‭as‬ ‭its‬ ‭edges‬ ‭raise‬ ‭from‬ ‭the‬ ‭plan.‬ ‭This‬
‭defect‬ ‭is‬ ‭related‬ ‭to‬ ‭cutting‬ ‭angle‬ ‭and‬ ‭plate‬ ‭strength.‬ ‭To‬ ‭reduce‬ ‭this‬ ‭effect‬ ‭it‬ ‭is‬
‭recommended‬ ‭to‬ ‭use‬ ‭a‬ ‭smaller‬‭shearing‬ ‭angle ‭a‬ nd‬ ‭to hold‬ ‭the‬ ‭sheet‬ ‭metal‬ ‭with‬
‭a ‬‭back support‬‭.‬
‭2.‬ ‭Crooking:‬ ‭This‬ ‭defect‬ ‭produces‬ ‭a‬ ‭plate‬ ‭that‬ ‭is‬ ‭curved‬ ‭along‬ ‭its‬ ‭plane‬ ‭(surface‬ ‭stays‬
‭flat).‬ ‭It‬ ‭is‬ ‭related‬ ‭to‬ ‭strip‬ ‭width,‬ ‭its‬ ‭thickness,‬ ‭material‬ ‭strength‬ ‭and‬ ‭previous‬ ‭cold‬
‭rolling‬ ‭direction‬ ‭(residual‬ ‭stresses).‬ ‭To‬ ‭reduce‬ ‭crooking‬ ‭it‬ ‭is‬ ‭recommended‬ ‭to‬ ‭use‬ ‭a‬
‭smaller shearing angle and to do pre-cuts along rolling direction.‬
‭3.‬ ‭Twist:‬ ‭This‬ ‭defect‬ ‭twists‬ ‭the‬ ‭plate‬‭along‬‭its‬‭axis.‬‭It‬‭typically‬‭happens‬‭when‬‭shearing‬
‭narrow‬‭strips‬‭(less‬‭than‬‭10‬‭times‬‭the‬‭thickness).‬‭Shearing‬‭conditions‬‭that‬‭increase‬‭this‬
‭defect‬ ‭are‬ ‭related‬ ‭to‬ ‭sheet‬ ‭metal‬ ‭geometry‬ ‭(high‬ ‭thickness,‬ ‭reduced‬ ‭width,‬ ‭short‬
‭length),‬ ‭material‬ ‭characteristics‬ ‭(soft‬ ‭material,‬ ‭uneven‬ ‭stress‬ ‭distribution)‬ ‭and‬ ‭of‬
‭course‬‭cutting‬‭parameters‬‭(high‬‭rake‬‭angle,‬‭high‬‭cutting‬‭speed).To‬‭reduce‬‭this‬‭defect‬‭it‬
‭is recommended to lower the rake angle. It is also useful to add an anti-twist device.‬

‭4.‬ C ‭ lose‬‭to‬‭the‬‭end‬‭of‬‭the‬‭shearing,‬‭material‬‭gives‬‭in‬‭and‬‭cracks,‬‭producing‬‭a‬‭rough‬‭and‬
‭irregular‬ ‭surface‬ ‭known‬ ‭as‬ ‭the ‭f‬ ractured‬ ‭zone (J)‬‭,‬ ‭which‬ ‭extends‬ ‭into‬ ‭the ‭e‬ dge‬
‭burr (K)‬‭.‬ ‭Fractured‬ ‭zone‬ ‭is‬ ‭often‬ ‭not‬ ‭perpendicular‬ ‭to‬ ‭the‬ ‭plate‬ ‭but‬ ‭at‬ ‭a ‭v‬ ariable‬
‭angle (L)‬‭.‬
‭To‬ ‭improve‬ ‭edge‬ ‭quality‬ ‭we‬ ‭must ‬‭adjust‬ ‭blade‬ ‭clearance ‬‭(distance‬ ‭between‬ ‭the‬
‭punch and the die), and keep blade wear under control.‬
 ‭Fig.5 : Shearing defects‬

‭Bending :‬
‭ ending‬‭is‬‭a‬‭process‬‭by‬‭which‬‭metal‬‭can‬‭be‬‭deformed‬‭by‬‭plastically‬‭deforming‬‭the‬‭material‬
B
‭and‬ ‭changing‬ ‭its‬ ‭shape.‬ ‭The‬ ‭material‬ ‭is‬ ‭stressed‬ ‭beyond‬ ‭the‬ ‭yield‬ ‭strength‬ ‭but‬ ‭below‬ ‭the‬
‭ultimate‬ ‭tensile‬ ‭strength.‬ ‭The‬ ‭surface‬ ‭area‬ ‭of‬ ‭the‬ ‭material‬ ‭does‬ ‭not‬ ‭change‬ ‭much.‬ ‭Bending‬
‭usually refers to deformation about one axis.‬

‭Common types of bending operation:‬

‭ ne‬‭of‬‭the‬‭most‬‭common‬‭types‬‭of‬‭sheet‬‭metal‬‭manufacturing‬‭processes‬‭is‬‭V‬‭bending.‬‭The‬‭V‬
O
‭shaped‬‭punch‬‭forces‬‭the‬‭work‬‭into‬‭the‬‭V‬‭shaped‬‭die‬‭and‬‭hence‬‭bends‬‭it.‬‭This‬‭type‬‭of‬‭process‬
‭can‬ ‭bend‬ ‭both‬ ‭very‬ ‭acute‬ ‭and‬ ‭very‬ ‭obtuse‬ ‭angles,‬ ‭also‬ ‭anything‬ ‭in‬ ‭between,‬ ‭including‬ ‭90‬
‭degrees.‬

‭ dge‬ ‭bending‬ ‭is‬ ‭another‬ ‭very‬ ‭common‬ ‭sheet‬ ‭metal‬ ‭process‬‭and‬‭is‬‭performed‬‭with‬‭a‬

E
‭wiping‬ ‭die.‬ ‭Edge‬ ‭bending‬ ‭gives‬ ‭a‬ ‭good‬ ‭mechanical‬ ‭advantage‬ ‭when‬ ‭forming‬ ‭a‬ ‭bend.‬
‭However,‬ ‭angles‬ ‭greater‬ ‭than‬ ‭90‬ ‭degrees‬ ‭will‬ ‭require‬ ‭more‬ ‭complex‬ ‭equipment,‬‭capable‬‭of‬
‭some‬ ‭horizontal‬ ‭force‬ ‭delivery.‬ ‭Also,‬ ‭wiping‬ ‭die‬ ‭employed‬ ‭in‬ ‭edge‬ ‭bending‬ ‭must‬ ‭have‬ ‭a‬
‭pressure‬ ‭pad.‬ ‭The‬ ‭action‬ ‭of‬ ‭the‬ ‭pressure‬ ‭pad‬ ‭may‬ ‭be‬ ‭controlled‬ ‭separately‬ ‭than‬ ‭that‬ ‭of‬ ‭the‬
‭punch.‬‭Basically‬‭the‬‭pressure‬‭pad‬‭holds‬‭a‬‭section‬‭of‬‭the‬‭work‬‭in‬‭place‬‭on‬‭the‬‭die,‬‭the‬‭area‬‭for‬
‭the‬ ‭bend‬ ‭is‬ ‭located‬ ‭on‬ ‭the‬ ‭edge‬‭of‬‭the‬‭die‬‭and‬‭the‬‭rest‬‭of‬‭the‬‭work‬‭is‬‭held‬‭over‬‭space‬‭like‬‭a‬
c‭ antilever‬ ‭beam.‬ ‭The‬ ‭punch‬ ‭then‬ ‭applies‬ ‭force‬ ‭to‬ ‭the‬ ‭cantilever‬ ‭beam‬ ‭section,‬ ‭causing‬ ‭the‬
‭work to bend over the edge of the die.‬

‭Fig.6 V-bending operation‬

‭Fig.7 Edge-bending or wipe-bending operation‬

‭Terminology and mechanics of Bending operation‬

‭ o‬ ‭understand‬ ‭the‬ ‭mechanics‬ ‭of‬ ‭sheet‬ ‭metal‬ ‭bending,‬ ‭an‬ ‭understanding‬ ‭of‬ ‭the‬ ‭material‬
T
‭properties,‬ ‭characteristics‬ ‭and‬ ‭behaviors‬ ‭of‬ ‭metal,‬ ‭is‬‭necessary.‬‭Particularly‬‭important‬‭is‬‭the‬
‭topic‬‭of‬‭elastic‬‭and‬‭plastic‬‭deformation‬‭of‬‭metal.‬‭It‬‭should‬‭be‬‭understood‬‭also‬‭that‬‭sheet‬‭metal‬
‭bending‬‭produces‬‭localized‬‭plastic‬‭deformation‬‭and‬‭essentially‬‭no‬‭change‬‭in‬‭sheet‬‭thickness,‬
‭for most operations. It does not create metal flow that affects regions away from the bend.‬
 ‭Fig.8 Terminology of bending operation‬

‭ eutral Axis:‬
N
‭It‬‭is‬‭an‬‭imaginary‬‭axis‬‭which‬‭does‬‭not‬‭undergo‬‭any‬‭stress‬‭during‬‭bending.‬‭The‬‭act‬‭of‬‭bending‬
‭results‬ ‭in‬ ‭both‬ ‭tension‬ ‭and‬ ‭compression‬ ‭in‬‭the‬‭sheet‬‭metal.‬‭The‬‭outside‬‭portion‬‭of‬‭the‬‭sheet‬
‭will‬ ‭undergo‬ ‭tension‬ ‭and‬ ‭stretch‬ ‭to‬ ‭a‬ ‭greater‬ ‭length,‬ ‭while‬ ‭the‬ ‭inside‬ ‭portion‬ ‭experiences‬
‭compression‬‭and‬‭shortens.‬‭The‬‭neutral‬‭axis‬‭is‬‭the‬‭boundary‬‭line‬‭inside‬‭the‬‭sheet‬‭metal,‬‭along‬
‭which‬ ‭no‬ ‭tension‬ ‭or‬ ‭compression‬ ‭forces‬ ‭are‬ ‭present.‬ ‭As‬ ‭a‬ ‭result,‬ ‭the‬ ‭length‬ ‭of‬ ‭this‬ ‭axis‬
‭remains‬ ‭constant.‬ ‭The‬ ‭changes‬ ‭in‬‭length‬‭to‬‭the‬‭outside‬‭and‬‭inside‬‭surfaces‬‭can‬‭be‬‭related‬‭to‬
‭the‬‭original‬‭flat‬‭length‬‭by‬‭two‬‭parameters,‬‭the‬‭bend‬‭allowance‬‭and‬‭bend‬‭deduction,‬‭which‬‭are‬
‭defined below.‬

‭ uter Fibers:‬
O
‭Those‬ ‭fibers‬ ‭which‬ ‭are‬ ‭under‬ ‭tension‬ ‭during‬ ‭the‬ ‭bending‬ ‭process,‬ ‭known‬ ‭as‬ ‭outer‬ ‭fibers.‬
‭These are at one side of the neutral axis. It is shown in red in figure.‬

I‭ nner Fibers: ‬
‭Those‬‭fibers‬‭which‬‭are‬‭under‬‭compression‬‭during‬‭the‬‭bending‬‭process,‬‭known‬‭as‬‭inner‬‭fibers.‬
‭These fibers are shown by blue color in figure.‬
‭Bend allowance :‬
‭The‬‭length‬‭of‬‭the‬‭neutral‬‭axis‬‭between‬‭the‬‭bend‬‭lines,‬‭or‬‭in‬‭other‬‭words,‬‭the‬‭arc‬‭length‬‭of‬‭the‬
‭bend. The bend allowance added to the flange lengths is equal to the total flat length.‬

‭Bend deduction ‬

‭ lso‬ ‭called‬ ‭the‬ ‭bend‬ ‭compensation,‬ ‭the‬ ‭amount‬ ‭a‬ ‭piece‬ ‭of‬ ‭material‬ ‭has‬ ‭been‬ ‭stretched‬ ‭by‬
A
‭bending. The value equals the difference between the bent length and the total flat length.‬

‭ end Allowance:‬
B
‭The length of the neutral axis in the bend zone is known as bend allowance.‬

‭ end Angle:‬
B
‭The angle formed by the bend area at the center of bend is known as bend angle.‬

‭ end Radius:‬
B
‭Distance between the bend center and neutral axis is known as bend radius. It is denoted by r.‬

‭ inimum Bend Radius:‬

M
‭The‬‭minimum‬‭bend‬‭radius‬‭is‬‭the‬‭bend‬‭radius‬‭at‬‭which‬‭a‬‭crack‬‭appears‬‭on‬‭the‬‭outer‬‭surface‬‭of‬
‭the‬ ‭bend.‬ ‭It‬ ‭is‬ ‭usually‬ ‭expressed‬ ‭in‬ ‭terms‬ ‭of‬ ‭sheet‬ ‭thickness,‬ ‭such‬ ‭as‬ ‭2T,‬ ‭3T,‬ ‭4T‬ ‭etc.‬ ‭It‬ ‭is‬
‭different for different materials.‬

‭ -factor :‬
K
‭The‬ ‭location‬ ‭of‬ ‭the‬‭neutral‬‭axis‬‭in‬‭the‬‭material,‬‭calculated‬‭as‬‭the‬‭ratio‬‭of‬‭the‬‭distance‬‭of‬‭the‬
‭neutral‬ ‭axis‬‭(measured‬‭from‬‭the‬‭inside‬‭bend‬‭surface)‬‭to‬‭the‬‭material‬‭thickness.‬‭The‬‭K-factor‬
‭is‬ ‭dependent‬ ‭upon‬ ‭several‬ ‭factors‬ ‭(material,‬ ‭bending‬ ‭operation,‬ ‭bend‬ ‭angle,‬ ‭etc.)‬ ‭and‬ ‭is‬
‭typically greater than 0.25, but cannot exceed 0.50.‬

‭Common defects and technological measures of bending workpieces‬

‭1) fracture‬

‭ fter‬‭the‬‭material‬‭is‬‭sheared‬‭or‬‭punched,‬‭burrs‬‭or‬‭small‬‭cracks‬‭often‬‭appear‬‭on‬‭the‬‭edge,‬‭and‬
A
‭it‬ ‭is‬ ‭easy‬ ‭to‬ ‭form‬ ‭stress‬ ‭concentration‬ ‭and‬ ‭be‬ ‭fractured‬ ‭when‬ ‭bending.‬ ‭It‬ ‭can‬ ‭be‬‭seen‬‭from‬
‭Figure‬‭1‬‭that‬‭the‬‭shear‬‭surface‬‭when‬‭the‬‭workpiece‬‭is‬‭fractured‬‭(burr‬‭surface)‬‭)‬‭Outwards,‬‭the‬
‭cracking‬ ‭position‬ ‭occurs‬ ‭in‬ ‭the‬ ‭shearing‬ ‭zone‬ ‭and‬ ‭kneading‬ ‭zone‬ ‭of‬ ‭the‬ ‭workpiece.‬ ‭The‬
‭technological measures taken for this are:‬
‭i)‬ ‭After‬ ‭shearing‬ ‭or‬ ‭punching‬ ‭the‬ ‭workpiece,‬ ‭ensure‬ ‭that‬ ‭the‬ ‭shearing‬ ‭face‬ ‭is‬ ‭inward‬ ‭when‬
‭bending, that is, it is under compression, as shown in Figure 2, the forming effect is better.‬
‭ii)‬ ‭Deburr‬ ‭the‬ ‭workpiece‬ ‭before‬ ‭bending,‬ ‭and‬ ‭use‬ ‭a‬ ‭manual‬ ‭grinding‬ ‭machine‬ ‭to‬ ‭grind‬ ‭the‬
‭broken part after bending.‬
 ‭Fig.9 Bending workpiece with different shear orientation‬

‭2) Spring back‬

‭ uring the bending process of metal materials, plastic deformation and elastic deformation‬
D
‭coexist. At the end of bending, springback occurs due to the recovery of elastic deformation,‬
‭as shown in Figure 3. The rebound phenomenon directly affects the dimensional accuracy of‬
‭the workpiece and must be controlled. The technological measures adopted for this are:‬
‭i) Angle compensation method. If the bending angle of the workpiece is 90 °, the opening‬
‭angle of the lower groove (V-shaped) of the Press Brake can be selected as 78 °.‬

i‭i) Correction method through increasing the compression time. Performing pressure‬
‭correction at the end of bending to extend the contact time of the upper die, workpiece and‬
‭lower groove of the Press Brake to increase the degree of plastic deformation at the corner of‬
‭the lower groove, and the rebound trends of the fibers in the tension and compression zone‬
‭can resist and reduce.‬

‭ ig.10 Springback in bending shows itself as a decrease in bend angle and an increase in‬
F
‭bend radius: (1) during the operation, the work is forced to take the radius Rt and included‬
‭angle ab determined by the bending tool (punch in V-bending); (2) after the punch is‬
‭removed, the work springs back to radius R and included angle a. Symbol: F applied bending‬
‭force.‬

‭Calculation for springback:‬

‭ hen‬‭the‬‭bending‬‭pressure‬‭is‬‭removed‬‭at‬‭the‬‭end‬‭of‬‭the‬‭deformation‬‭operation,‬‭elastic‬‭energy‬
W
‭remains‬‭in‬‭the‬‭bent‬‭part,‬‭causing‬‭it‬‭to‬‭recover‬‭partially‬‭toward‬‭its‬‭original‬‭shape.‬‭This‬‭elastic‬
‭recovery‬ ‭is‬ ‭called‬ ‭springback,‬ ‭defined‬ ‭as‬ ‭the‬ ‭increase‬ ‭in‬ ‭included‬ ‭angle‬ ‭of‬ ‭the‬ ‭bent‬ ‭part‬
‭relative‬‭to‬‭the‬‭included‬‭angle‬‭of‬‭the‬‭forming‬‭tool‬‭after‬‭the‬‭tool‬‭is‬‭removed.‬‭This‬‭is‬‭illustrated‬
‭in figure 4.‬

‭SB = (α’ - α'‬‭b‭)‬ /α'‬‭b‬

‭ B = spring back, α’ included angle of the sheet-metal part, degrees; and α'‬‭b‬ ‭included angle of‬
S
‭the bending tool, degrees.‬

‭Calculation of springback using material properties-‬

‭Where,‬

‭ϴ = Spring back of one side‬

‭α = Bend angle to be achieved‬

‭r‬‭p‬ ‭= Nose radius of punch‬

‭t = Sheet thickness‬

‭M = Bending Moment‬

‭E = Young’s Modulus of material‬

‭Limitations of the process:‬

‭1.‬‭During the drawing process defects such as wrinkling,‬‭tearing, earing can be obtained.‬

‭2.‬ ‭For a new shape a new die and punch needs‬‭to be designed.‬
 ‭3.‬ ‭Costly process.‬

‭4.‬ ‭Orange peeling effect is sometimes observed‬‭in the formed part.‬

‭References:‬

‭1.‬ M ‭ .‬ ‭P.‬ ‭Groover,‬ ‭“Fundamentals‬ ‭of‬ ‭Modern‬ ‭Manufacturing:‬ ‭Materials,‬ P ‭ rocesses,‬ ‭and‬
‭Systems,” John Wiley & Sons.‬
‭2.‬ ‭Design‬ ‭Guidelines‬ ‭for‬ ‭sheet‬ ‭metal‬ ‭working‬ ‭by‬ ‭Dr.‬ ‭Inderdeep‬ ‭singh,‬ ‭Department‬ ‭of‬
‭Mechanical and industrial Engineering, IIT Roorkee. (NPTEL lectures)‬

‭Assignment‬

‭1.‬ C ‭ alculate‬ ‭the‬ ‭cutting‬‭force‬ ‭in‬‭sheet‬‭metal‬‭working‬‭for‬‭the‬‭mild‬‭steel‬‭and‬‭aluminium‬

‭sheet as per the data given in Table 1.‬
‭2.‬ ‭Calculate‬ ‭the‬‭Spring‬‭back‬‭(SB)‬‭in‬‭bending‬‭process‬‭for‬‭mild‬‭steel‬‭and‬‭aluminium‬‭for‬
‭the data listed in Table 2.‬
‭3.‬ ‭Discuss‬ ‭the‬ ‭effects‬ ‭of‬ ‭material‬ ‭properties‬ ‭and‬ ‭thickness‬ ‭on‬ ‭the‬ ‭cutting‬ ‭force‬ ‭in‬
‭shearing and spring back in bending.‬

‭Table 1. Experimental data for obtaining cutting force.‬

‭S. no.‬ ‭Material‬ ‭Shear Strength‬ ‭Length‬ ‭Thickness‬ ‭ utting‬

C
‭(N/mm‬‭2‬‭)‬ ‭(mm)‬ ‭(mm)‬ ‭Force (N)‬

‭1.‬ ‭Mild Steel‬ ‭210‬ ‭100‬ ‭.5‬

‭(MS)‬
‭1‬

‭2.‬ ‭Aluminium‬ ‭205‬ ‭100‬ ‭1‬

‭(Al)‬
‭3‬

‭Table 2. Experimental data for obtaining spring back.‬

‭S. no.‬ ‭Material‬ ‭Thickness‬ ‭Spring Back‬

‭(mm)‬ ‭α’ (°)‬ ‭α'‬‭b‬‭(°)‬ ‭(SB)‬

‭1.‬ ‭Mild Steel‬ ‭0.5‬ ‭90‬ ‭91.63‬

‭(MS)‬
‭1‬ ‭90‬ ‭90.95‬

‭2.‬ ‭Aluminium‬ ‭1‬ ‭90‬ ‭94‬

‭(Al)‬