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© 2011 Su-Jin Kim GNU © 2011 Su-Jin Kim GNU Sheet-Metal Forming Sheet-Metal Forming Manufacturing Processes Manufacturing Processes Manufacturing Processes Manufacturing Processes Sheet Metal Forming Sheet Metal Forming 판판 판판 판판 판판 Associate Professor Su-Jin Kim School of Mechanical Engine ering

© 2011 Su-Jin Kim GNU Sheet-Metal Forming Manufacturing Processes Sheet Metal Forming 판재 성형 Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical

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Page 1: © 2011 Su-Jin Kim GNU Sheet-Metal Forming Manufacturing Processes Sheet Metal Forming 판재 성형 Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical

© 2011 Su-Jin Kim GNU© 2011 Su-Jin Kim GNU

Sheet-Metal FormingSheet-Metal FormingManufacturing ProcessesManufacturing Processes

Manufacturing Processes Manufacturing Processes

Sheet Metal FormingSheet Metal Forming판재 성형판재 성형

Associate Professor Su-Jin Kim

School of Mechanical EngineeringGyeongsang National University

Page 2: © 2011 Su-Jin Kim GNU Sheet-Metal Forming Manufacturing Processes Sheet Metal Forming 판재 성형 Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical

© 2011 Su-Jin Kim GNU© 2011 Su-Jin Kim GNU

Sheet-Metal FormingSheet-Metal FormingManufacturing ProcessesManufacturing Processes

Sheet metal forming ( 판재성형 )

• Sheet metal forming is a processes that shape a piece of sheet metal into the desired part through shearing( 전단 ) and deformation( 성형 ).

• It is also called pressworking, press forming, or stamping.

Page 3: © 2011 Su-Jin Kim GNU Sheet-Metal Forming Manufacturing Processes Sheet Metal Forming 판재 성형 Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical

© 2011 Su-Jin Kim GNU© 2011 Su-Jin Kim GNU

Sheet-Metal FormingSheet-Metal FormingManufacturing ProcessesManufacturing Processes

Contents

1. [Shearing]2. [Forming]3. [Press Die]

Page 4: © 2011 Su-Jin Kim GNU Sheet-Metal Forming Manufacturing Processes Sheet Metal Forming 판재 성형 Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical

© 2011 Su-Jin Kim GNU© 2011 Su-Jin Kim GNU

Sheet-Metal FormingSheet-Metal FormingManufacturing ProcessesManufacturing Processes

Cutting with Shearing ( 전단 )• Sheet metal is separated by applying shearing force

using punch and die.• Edge fracture & burr.

Punch

Sheet metal

Die

F

Clearance

Rollover

Burnish

Fracture

Burr

Page 5: © 2011 Su-Jin Kim GNU Sheet-Metal Forming Manufacturing Processes Sheet Metal Forming 판재 성형 Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical

© 2011 Su-Jin Kim GNU© 2011 Su-Jin Kim GNU

Sheet-Metal FormingSheet-Metal FormingManufacturing ProcessesManufacturing Processes

Cutting with shear

1. Shearing - Separating material into two parts 2. Blanking - Removing material to use for parts 3. Punching - Removing material as scrap

Blanking

Scrap

Part

Punching

Part

Scrap

Shearing

Part2Part1

Page 6: © 2011 Su-Jin Kim GNU Sheet-Metal Forming Manufacturing Processes Sheet Metal Forming 판재 성형 Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical

© 2011 Su-Jin Kim GNU© 2011 Su-Jin Kim GNU

Sheet-Metal FormingSheet-Metal FormingManufacturing ProcessesManufacturing Processes

Shearing

• Shearing cuts straight line to separate a piece of sheet metal into smaller parts.

Page 7: © 2011 Su-Jin Kim GNU Sheet-Metal Forming Manufacturing Processes Sheet Metal Forming 판재 성형 Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical

© 2011 Su-Jin Kim GNU© 2011 Su-Jin Kim GNU

Sheet-Metal FormingSheet-Metal FormingManufacturing ProcessesManufacturing Processes

Blanking

• Desired part (gears, key) is removed from sheet metal.• Fine blanking, applying 3 separate forces, produces

smooth and flat edges with minimal burrs and tolerances.

Punch

Upper pressure pad

Sheet metal

DieLower pressure cushion

Stringer

BlankingFineblanking

http://ma.gnu.ac.kr/vod/forming/Stainless_Spoon.wmv Spoon

Page 8: © 2011 Su-Jin Kim GNU Sheet-Metal Forming Manufacturing Processes Sheet Metal Forming 판재 성형 Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical

© 2011 Su-Jin Kim GNU© 2011 Su-Jin Kim GNU

Sheet-Metal FormingSheet-Metal FormingManufacturing ProcessesManufacturing Processes

Punching

Scrap(Hole, slot) is removed from sheet metal.•Piercing - cylindrical punch •Slotting - rectangular holes •Perforating - large number of holes •Notching - edge of sheet •Lancing - partial cut to be bent •Slitting - straight line •Parting - separating a part•Cutoff - separating a part

Page 9: © 2011 Su-Jin Kim GNU Sheet-Metal Forming Manufacturing Processes Sheet Metal Forming 판재 성형 Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical

© 2011 Su-Jin Kim GNU© 2011 Su-Jin Kim GNU

Sheet-Metal FormingSheet-Metal FormingManufacturing ProcessesManufacturing Processes

Punch Force

• The punch force is product of shear strength of sheet metal and cross-sectional area being sheared.

• Punch force : F ≈ (0.7σu)tl σu = ultimate tensile strengtht = thicknessl = total length of the sheared edge

t

l

F

Page 10: © 2011 Su-Jin Kim GNU Sheet-Metal Forming Manufacturing Processes Sheet Metal Forming 판재 성형 Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical

© 2011 Su-Jin Kim GNU© 2011 Su-Jin Kim GNU

Sheet-Metal FormingSheet-Metal FormingManufacturing ProcessesManufacturing Processes

Estimate the force required in punching a 25 mm diameter hole through a1.8 mm thick 5052-O aluminium sheet at room temperature. Ultimate tensile strength of it is 190 MPa.

SolutionF = (0.7 190 Mpa) (1.8 π 25 mm2) = 18.8 kN

Ex) Calulation of punch force

Page 11: © 2011 Su-Jin Kim GNU Sheet-Metal Forming Manufacturing Processes Sheet Metal Forming 판재 성형 Associate Professor Su-Jin KimSu-Jin Kim School of Mechanical

© 2011 Su-Jin Kim GNU© 2011 Su-Jin Kim GNU

Sheet-Metal FormingSheet-Metal FormingManufacturing ProcessesManufacturing Processes

Punch press machine

• Punch press

bending tool

http://www.youtube.com/watch?v=vdqqm0Hi7nc LVD

http://www.youtube.com/watch?v=DvONyl-ncMo AMADA