Ch16 sheet metal forming
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Transcript of Ch16 sheet metal forming
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Chapter 16Sheet-Metal Forming Processes
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Sheet-Metal Parts
(a) (b)
Figure 16.1 Examples of sheet-metal parts. (a) Die-formed and cut stamped parts.(b) Parts produced by spinning. Source: (a) Courtesy of Aphase II, Inc. (b)Courtesy of Hialeah Metal Spinning, Inc.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Characteristics of Sheet-Metal Forming Processes
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Shearing with aPunch and Die
Figure 16.2 (a) Schematic illustration ofshearing with a punch and die, indicatingsome of the process variables.Characteristic features of (b) a punchedhole and (c) the slug. (Note: The scalesof the two figures are different.)
!
Punch force, F = 0.7TL UTS( )
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Shearing
Figure 16.3 (a) Effect of the clearance, c, between punch and die on the deformation zonein shearing. As the clearance increases, the material tends to be pulled into the die ratherthan be sheared. In practice, clearances usually range between 2 and 10% of the thicknessof the sheet. (b) Microhardness (HV) contours for a 6.4-mm (0.25-in.) thick AISI 1020 hot-rolled steel in the sheared region. Source: After H.P Weaver and K.J. Weinmann.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Die-Cutting Operations
Figure 16.4 (a) Punching (piercing) and blanking.(b) Examples of various die-cutting operations onsheet metal.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Conventional Versus Fine-Blanking
Figure 16.5 (a) Comparison of sheared edges produced by conventional (left) andby fine-blanking (right) techniques. (b) Schematic illustration of one setup for fineblanking. Source: Courtesy of Feintool U.S. Operations.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Slitting with Rotary Knives
Figure 16.6 Slitting with rotary knives. This process is similar to opening cans.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Tailor-Welded Blanks
Figure 16.7 Production of an outer side panel of a car body by laser butt-welding and stamping. Source: After M. Geiger and T. Nakagawa.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Examples of Automotive ComponentsProduced from Tailor-Welded Blanks
Figure 16.8 Examples of laser butt-welded and stamped automotive-body components.Source: After M. Geiger and T. Nakagawa.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
The Shaving Process
Figure 16.9 Schematic illustrations of the shaving process. (a) Shaving a shearededge. (b) Shearing and shaving combined in one stroke.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Shear Angles
Figure 16.10 Examples of the use of shear angles on punches and dies.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
CompoundDie and
ProgressiveDie
Figure 16.11 Schematic illustrations: (a) before and (b) after blanking a common washer in acompound die. Note the separate movements of the die (for blanking) and the punch (forpunching the hole in the washer). (c) Schematic illustration of making a washer in aprogressive die. (d) Forming of the top piece of an aerosol spray can in a progressive die.Note that the part is attached to the strip until the last operation is completed.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Characteristics of Metals Used in Sheet-Forming
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Sheet Metal
Figure 16.12 (a) Yield-point elongation in a sheet-metal specimen. (b) Luder’s bandsin a low-carbon steel sheet. (c) Stretcher strains at the bottom of a steel can forhousehold products. Source: (b) Courtesy of Caterpillar Inc.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Cupping Test and Bulge-Test
Figure 16.13 (a) A cupping test (the Erichsen test) to determine the formability of sheetmetals. (b) Bulge-test results on steel sheets of various widths. The specimen farthestleft is subjected to, basically, simple tension. The specimen farthest right is subjected toequal biaxial stretching. Source: Courtesy of Inland Steel Company.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Forming Limit Diagram
Figure 16.14 (a) Strains indeformed circular gridpatterns. (b) Forming-limitdiagrams (FLD) for varioussheet metals. Although themajor strain is always positive(stretching), the minor strainmay be either positive ornegative. In the lower left ofthe diagram, R is the normalanisotropy of the sheet, asdescribed in Section 16.4.Source: After S .S Hecker andA. K. Ghosh.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Deformation and Tearing in Sheet Metal During Forming
Figure 16.15 The deformation of the grid pattern and the tearing of sheet metal duringforming. The major and minor axes of the circles are used to determine the coordinateson the forming-limit diagram in Fig. 16.14b. Source: After S. P. Keeler.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Bending Terminology
Figure 16.16 Bending terminology. Note that the bendradius is measured to the inner surface of the bent part.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Effect of Elongated Inclusions
Figure 16.17 (a) and (b) The effect of elongated inclusions stringers) oncracking as a function of the direction of bending with respect to the originalrolling direction of the sheet. (c) Cracks on the outer surface of an aluminumstrip bent to an angle of 90 degrees. Note also the narrowing of the top surfacein the bend area (due to Poisson effect).
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Minimum Bend Radius
Figure 16.18 Relationship between R/T ratio and tensile reduction of area for sheet metals.Note that sheet metal with 50% tensile reduction of area can be bent over itself in a processlike the folding of a piece of paper without cracking. Source: After J. Datsko and C. T.Yang.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Springback in Bending
Figure 16.19 Springback in bending. The part tends to recover elastically after bending,and its bend radius becomes larger. Under certain conditions, it is possible for the finalbend angle to be smaller than the original angle (negative springback).
!
Ri
Rf
= 4RiY
ET
"
# $
%
& ' 3
( 3RiY
ET
"
# $
%
& ' +1
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Methods of Reducing or Eliminating Springback
Figure 16.20 Methods of reducing or eliminating springback in bendingoperations. Source: After V. Cupka, T. Nakagawa, and H. Tyamoto.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Common Die-Bending Operations
Figure 16.21 Common die-bending operationsshowing the die-opening dimension, W, used incalculating bending forces.
Bending Force
!
P =kYLT
2
W
where
k = 0.3 for wiping die,
k = 0.7 for a U - die,
k =1.3 for a V- die
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Bending Operations
Figure 16.22 Examples of various bending operations.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Press Brake
Figure 16.23 (a) through (e) Schematic illustrations of various bending operations in apress brake. (f) Schematic illustration of a press brake. Source: Courtesy of VersonAllsteel Company.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Bead Forming
Figure 16.24 (a) Bead forming with a single die. (b) and (c) Beadforming with two dies in a press brake.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Flanging OperationsFigure 16.25 Variousflanging operations. (a)Flanges on a flat sheet.(b) Dimpling. (c) Thepiercing of sheet metal toform a flange. In thisoperation, a hole doesnot have to be pre-punched before thepunch descends. Note,however, the roughedges along thecircumference of theflange. (d) The flangingof a tube. Note thethinning of the edges ofthe flange.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Roll-Forming Process
Figure 16.26 (a) Schematic illustration of the roll-forming process. (b)Examples of roll-formed cross-sections. Source: (b) Courtesy of SharonCustom Metal Forming, Inc.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Methods of Bending Tubes
Figure 16.27 Methods of bending tubes. Internal mandrels or filling of tubes withparticulate materials such as sand are often necessary to prevent collapse of the tubesduring bending. Tubes also can be bent by a technique consisting if a stiff, helical tensionspring slipped over the tube. The clearance between the OD of the tube and the ID of thespring is small, thus the tube cannot kick and the bend is uniform.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Tubular Parts
Figure 16.28 (a) The bulging of a tubular part with a flexible plug. Water pitcherscan be made by this method. (b) Production of fittings for plumbing by expandingtubular blanks under internal pressure. The bottom of the piece is then punchedout to produce a “T.” Source: After J. A. Schey.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing of Bellows
Figure 16.29 Steps in manufacturing a bellows.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Stretch-Forming Process
Figure 16.30 Schematic illustration of a stretch-forming process. Aluminum skinsfor aircraft can be made by this method. Source: Courtesy of Cyril Bath Co.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
CanManufacture
Figure 16.31 The metal-forming processesinvolved in manufacturinga two-piece aluminumbeverage can.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Deep-Drawing
Figure 16.32 (a) Schematic illustration of the deep-drawing process on a circular sheet-metal blank. The stripper ring facilitates the removal of the formed cup from the punch.(b) Process variables in deep drawing. Except for the punch force, F, all the parametersindicated on the figure are independent variables.
!
Fmax
= "DpT UTS( )Do
Dp
#
$ %
&
' ( ) 0.7
*
+ , ,
-
. / /
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Normal and Average Anisotropy
Figure 16.33 Strains on atensile-test specimenremoved form a piece ofsheet metal. These strainsare used in determining thenormal and planaranisotropy of the sheetmetal.
!
Normal anisotropy, R =Width strain
Thickness strain="w
"t
Average anisotropy, Ravg =R0 + 2R45 +R90
4
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Relationship between Average Normal Anisotropyand the Limiting Drawing Ratio
Figure 16.34 The relationship betweenaverage normal anisotropy and the limitingdrawing ratio for various sheet metals. Source:After M. Atkinson.
!
LDR =Maximum blank diameter
Punch diameter=Do
Dp
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Earing and Planar Anisotropy
Figure 16.35 Earing in a drawn steel cup causedby the planar anisotropy of the sheet metal.
!
Planar anisotropy, "R =R0 # 2R45 +R90
2
Note: If ΔR=0, no ears form.The height of ears increases asΔ R increases.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Drawbeads
Figure 16.36 (a) Schematic illustration of a draw bead. (b) Metal flow during thedrawing of a box-shaped part while using beads to control the movement of the material.(c) Deformation of circular grids in the flange in deep drawing.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Embossing with Two Dies
Figure 16.37 An embossing operation with two dies. Letters, numbers,and designs on sheet-metal parts can be produced by this process.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Aluminum Beverage Cans
Figure 16.38 (a) Aluminum beverage cans. Note the excellent surface finish.(b) Detail of the can lid showing integral rivet and scored edges for the pop-top.
(a)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Bending and Embossing of Sheet Metal
Figure 16.39 Examples of the bending and embossing of sheet metal with a metalpunch and with a flexible pad serving as the female die. Source: Courtesy ofPolyurethane Products Corporation.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Hydroform Process
Figure 16.40 The hydroform (or fluid-forming) process. Note that in contrast to theordinary deep-drawing process, the pressure in the dome forces the cup walls against thepunch. The cup travels with the punch; in this way, deep drawability is improved.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Tube-Hydroforming
Figure 16.41 (a) Schematic illustration ofthe tube-hydrofroming process. (b) Exampleof tube-hydroformed parts. Automotiveexhaust and structural components, bicycleframes, and hydraulic and pneumatic fittingsare produced through tube hydroforming.Source: Courtesy of Schuler GmBH.
(b)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Conventional Spinning
Figure 16.42 (a) Schematic illustration of the conventional spinning process.(b) Types of parts conventionally spun. All parts are axisymmetric.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Shear-Spinning and Tube-Spinning
Figure 16.43 (a) Schematic illustration of the shear-spinning process for makingconical parts. The mandrel can be shaped so that curvilinear parts can be spun. (b)and (c) Schematic illustrations of the tube-spinning process
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Structures Made by Diffusion Bonding and SuperplasticForming of Sheet Metals
Figure 16.44 Types of structures made by diffusion bonding and superplastic forming ofsheet metals. Such structures have a high stiffness-to-weight ratio. Source: Courtesy ofRockwell International Corp.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Explosive Forming
Figure 16.45 (a) Schematic illustration of the explosive forming process.(b) Illustration of the confined method of the explosive bulging of tubes.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Magnetic-Pulse Forming Process
Figure 16.46 (a) Schematic illustration of the magnetic-pulse forming process used to forma tube over a plug. (b) Aluminum tube collapsed over a hexagonal plug by the magnetic-pulse forming process.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
CymbalManufacture
Figure 16.47 (a) A selection of commoncymbals. (b) Detailed view of differentsurface textures and finishes of cymbals.Source: Courtesy of W. Blanchard, SabianLtd.
(a)
(b)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Cymbal Manufacture(cont.)
Figure 16.48 Manufacturing sequence forthe production of cymbals. Source:Courtesy of W. Blanchard, Sabian Ltd.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Hammering of Cymbals
Figure 16.49 Hammering of cymbals. (a) Automated hammering on a peening machine;(b) hand hammering of cymbals. Source: Courtesy of W. Blanchard, Sabian Ltd.
(a) (b)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Honeycomb Structures
Figure 16.50 Methods of manufacturing honeycomb structures: (a) expansion process;(b) corrugation process; (c) assembling a honeycomb structure into a laminate.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Efficient Part Nesting for Optimum Material Utilization
Figure 16.51 Efficient nesting of parts for optimum material utilization in blanking.Source: Courtesy of Society of Manufacturing Engineers.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Control of Defects in a Flange
Figure 16.52 Control of tearing and buckling of a flange in a right angle bend.Source: Courtesy of Society of Manufacturing Engineers.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Application of Notches
Figure 16.53 Application of notches to avoid tearing and wrinkling in right-anglebending operations. Source: Courtesy of Society of Manufacturing Engineers.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Stress Concentration Near Bends
Figure 16.54 Stress concentration near bends. (a) Use of a crescent or ear for a holenear a bend. (b) Reduction of severity of tab in flange. Source: Courtesy of Society ofManufacturing Engineers.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Obtaining a Sharp Radius in Bending
Figure 16.55 Application of scoring or embossing to obtain a sharp inner radius inbending. Unless properly designed, these features can lead to fracture. Source:Courtesy of Society of Manufacturing Engineers.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Presses
Figure 16.56 (a) through (f)Schematic illustrations oftypes of press frames forsheet-forming operations.Each type has its owncharacteristics of stiffness,capacity, and accessibility. (g)A large stamping press.Source: (a) through (f)Engineer’s Handbook, VEBFachbuchverlag, 1965. (g)Verson Allsteel Company.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Cost of Conventional Spinning Versus Cost of Deep Drawing
Figure 16.57 Cost comparison for manufacturing a round sheet-metal container either byconventional spinning or by deep drawing. Note that for small quantities, spinning is moreeconomical.