lec11a - Sheet Sheet Metal Forming Shearing Shearing...

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Sheet Metal Forming Shearing Sheet Metal Forming – Bending Lecture 11.a ISE 2204 – Introduction to Manufacturing Processes Dr. Jaime Camelio March 31 st , 2009 Mechanics of Sheet Metal Forming Neck Formation Shearing Processes Bending Processes ISE 2204 – Introduction to Manufacturing Processes – Spring 2009 Outline
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Involves workpieces with a high ratio of surface area to thickness Sheets are usually produced by rolling process Blank is cut from the sheet by a shearing process Then otherwise formed Low carbon steel and aluminum are the most common metal used for sheet metal product because of their formability and strength. ISE 2204 – Introduction to Manufacturing Processes – Spring 2009 Sheet Forming General characteristics of sheet-metal forming processes ISE 2204 – Introduction to Manufacturing Processes – Spring 2009 Sheet Sheet-Metal Forming Processes Metal Forming Processes
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Mechanics of all sheet forming consists of stretching and bending Thickness decreases lead to necking and failure (like in a tension test) P t th t i fl Parameters that influence: Elongation Yield-point elongation Anisotropy Grain size Residual stresses Springback ISE 2204 – Introduction to Manufacturing Processes – Spring 2009 Sheet Metal Characteristics Wrinkling a) Elongation: since material is usually stretched in a sheet forming, high uniform elongation is desirable for good formability ( σ =K ε n ). Also, a diffuse neck is desirable in sheet forming operations ( σ =C έ m ). b) Yield-point elongation: it results to luder’s band and (stretchers- t i k ) th h t Th l t d strain marks or worm) on the sheet. These elongated depressions should be avoided by reducing elongation using cold rolling process c) Anisotropy: The directional dependence of the material property affects the formability. d) Grain size: The smaller the grain size, the stronger is the metal e) Dent resistance of sheet metal: This is the resistance to sudden impact of a moving object Thus it is a dynamic yield stress ISE 2204 – Introduction to Manufacturing Processes – Spring 2009 Elongation impact of a moving object .Thus, it is a dynamic yield stress rather than a static yield stress. This can be increased by; (i)
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