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Chapter 5

The document discusses different types of bending dies, drawing dies, and deep drawing dies. It describes bending, springback, and methods to minimize springback. It also discusses die classifications based on operations, stations, materials, and production quantities. Deep drawing is described as a process that draws sheet metal into a forming die using a punch.

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67 views15 pages

Chapter 5

The document discusses different types of bending dies, drawing dies, and deep drawing dies. It describes bending, springback, and methods to minimize springback. It also discusses die classifications based on operations, stations, materials, and production quantities. Deep drawing is described as a process that draws sheet metal into a forming die using a punch.

Uploaded by

Gemeda
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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CHAPTER 5

Design of punches, bending dies,


drawing dies and Forging Dies
5.1. Bending
 Bending is the operation of deforming a flat sheet around
a straight axis where the neutral plane lies. It is a very
common forming process for changing the sheets and
plates into channel, drums, tanks, etc. Two different
scheme of bending are shown in the figure below.
 Bending is a metal forming process in which a force is
applied to a piece of sheet metal, causing it to bend at an
Tools Jigs and Die Design
1
angle and form the desired shape.
Spring back is a major problem during bending
of sheets that occurs due to elastic recovery by the
material causing a decrease in the bend angle once
the pressure is removed.
The springback can be minimized by introducing
excess amount of bending so that the finished
bending angle is the same after the elastic
recovery. However, a careful estimate of the
elastic recovery based on the mechanical behavior
of the sheet material is necessary to achieve the
same.
2
3
Cont’…

4
Tools Jigs and Die Design
There are other methods like the ironing of the strip to
compensate for these phenomena. There are basically
three types of bending dies:
 ‘U’ or Channel bends
Wiping bends
‘V’ bends

5 Tools Jigs and Die Design


6
5.2 Drawing Dies
In this die, the blank is drawn in the form of a cup by the
displacement of either a punch or a die, depending on the
selection and design. Barring the material which is in
contact with the bottom of the punch, there is no sizeable
stress distribution in this portion; rest of the material of the
blank takes the cylindrical shape from its original
concentric circular shapes.
Force required to draw the material should be optimum
and should neither be chosen higher nor lower than that is
required, as a higher force may tear the bottom portion of
the cup from the cylindrical portion and a lower force may
create wrinkles on the surface.
By descending order of the magnitude, forces due to
blanking
7 are the highest, followed by the drawing forces,
Die Classifications
5.2.1 Manufacturing processes
blanking dies, punching dies,
bending dies, drawing dies, et al.
5.2.2 Number of operations
single-operation dies----simple/plain dies
multi-operation dies----combination/compound
dies
----progressive dies

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Cont’….
5.2.3 Number of stations
Single station dies
Multi-station dies----progressive dies
Single station dies may be :
Combination (a die in which both cutting and
noncutting operations are accomplished at one
press stroke) or
Compound (a die in which two or more cutting
operations are accomplished at every press
stroke).
9 Tools Jigs and Die Design
Cont’…..
5.2.4 Die material
carbide,rubber, polyester,
polyurethane, zinc alloy, etc
5.2.5 Production quantities of pieces
Class A—high, best of materials
Class B—medium, cheaper materials, die cost
Class C—low-volume, cheapest
Temporary dies—small, lowest cost

10 Tools Jigs and Die Design


Fig. Drawing with a Blank Holder-Specific Example

11
5.3 Deep drawing
Deep drawing is a sheet metal forming process in which a
sheet metal blank is radially drawn into a forming die by
the mechanical action of a punch. It is thus a shape
transformation process with material retention.
The process is considered "deep" drawing when the depth
of the drawn part exceeds its diameter. This can be
achieved by redrawing the part through a series of dies.
The important variables in the technical components of
deep drawing dies are the punch corner radius, the die
ring profile, the clearance between punch and die ring,
and the configuration of the surfaces of the die rings and
the blank holder that are in contact with the blank.
12 Tools Jigs and Die Design
13 Tools Jigs and Die Design
A blank holder is used to prevent the formation of
wrinkles when the compressive action rearranges the
metal from the flange to the sidewall. In case of thick
sheets, the maximum percentage reduction in blank
diameter to cup diameter will be 25% for drawing without
blank holders, and if blank holders are employed, the
percentage reduction can go up to 50% for metals having
good drawability characteristics.

14 Tools Jigs and Die Design


Thank
you!
15 Tools Jigs and Die Design

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