MA2024 Tutorial 7
Metal Forming
Zhou Wei
[Link]
Part 1: Punching &
Blanking (Questions 1-2)
Question 1. A compound die will be used to blank and punch a large
washer out of 6061ST aluminum alloy sheet stock 3.50 mm thick. The
outside diameter of the washer is 50.0 mm and the inside diameter is
15.0 mm. Determine (a) the punch and die sizes for the blanking
operation, (b) the punch and die sizes for the punching operation, and
(c) the total force required if the blanking and punching operation are
done simultaneously and the tensile strength of the aluminum = 310
MPa.
Table: Clearance allowance value
Allowance
Metal Group
Ac
1100S and 5052S aluminum alloys,
0.045
all tempers
2024ST and 6061ST aluminum
0.060
alloys; brass, soft cold rolled steel,
soft stainless steel
Cold rolled steel, half hard; stainless 0.075
steel, half hard and full hard
• How to calculate clearance?
c = Act (or expressed as % of
sheet-metal thickness)
Ac = clearance allowance
Table: Clearance allowance value
Metal group Ac
1100S and 5052S aluminium alloys, all tempers. 0.045
2024 ST and 6061ST aluminium alloys; brass, all 0.060
tempers; soft cold rolled steel, soft stainless steel.
Cold rolled steel, half hard; stainless steel, half hard 0.075
and full hard. 4
Compound Die?
Performed more than
one operation with one
stroke of the press
producing the part
possibly with no or
minimal post
processing required.
5
Solution to Q1:
Compound die
Washer : Outside = 50.0 mm, Inside = 15.0 mm
t = 3.5 mm, Ac= 0.060 50.0
Find punch and die dimensions 15.0
Clearance c = Ac t = 0.060 × 3.5
= 0.21 mm
(a) For blanking operation
Blank diameter Db = 50.0 mm
Die = 50.00 mm
Punch = Db - 2c = 50.0 - 2 × 0.21 = 49.58 mm 6
50.0
(b) – for punching operation 15.0
Hole diameter Dh = 15.0 mm
Punch = 15.00 mm
Die = Dh+2 c = 15.0 +2×0.21 = 15.42 mm
(c) Find minimum press capacity (force)
Blanking and punching occur simultaneously
Tensile strength TS = 310 MPa
F = 0.7 × TS × t L
= 0.7 × 310 × 3.5 × ( 50.0 + 15.0)
= 155,092 N (unit!)
7
Further Question: The punches are
staggered so that punching occurs first and
then blanking.
Minimum press capacity (force) – 50.0
take maximum length L
15.0
F = 0.7 × TS × t L
= 0.7 × 310 × 3.5 × ( 50)
= 119,302 N
8
Question 2. A blanking die is to be designed to blank the
part outline shown in the figure. The material is 3 mm thick
stainless steel (half hard). Determine the dimensions of the
blanking punch and the die opening.
Make a drawing to represent the dimensions of the
cross-section of the punch and die.
Table: Clearance allowance value
Allowance
Metal Group
a
1100S and 5052S aluminum alloys,
0.045
all tempers
2024ST and 6061ST aluminum
0.060
alloys; brass, soft cold rolled steel,
soft stainless steel
Cold rolled steel, half hard; stainless 0.075
steel, half hard and full hard
All dimensions in mm
Solution to Q2
die
From the table, Ac = 0.075. Thus, c =
0.0753.0 = 0.225 mm
Blanking die: dimensions are the same as
for the part in Figure 1.
Blanking punch:
85 mm length dimension = 85 - 2 0.225
49.55
= 84.55 mm
50 mm width dimension = 50 - 20.225 punch 24.55
= 49.55 mm
84.55
Top and bottom 25 mm extension widths
= 25 - 20.225 24.55
= 24.55 mm 24.55
Note: The 25 mm inset dimension remains the same
(clearance accounted for on the 50 mm dimension).
All dimensions in mm
Part 2: Bending
(Question 3)
- It is important to know how
to calculate bend allowance
Question 3. A bending operation is to be performed
on 5.00 mm thick cold-rolled steel. The part drawing
is given in the figure. Determine the blank size
required.
11.35
All dimensions in mm
Solution to Q3
From drawing, α’ = 40°, R = 11.35 mm
α = 180 - α’ = 140°.
Ab = 2π(α/360)(R + Kbat)
R/t = 11.35/5.00 = 2.270; therefore, Kba = 0.5 (R > 2t)
Ab = 2π(140/360)(11.35 + 0.5 x 5.00) = 33.84 mm
Dimensions of starting blank:
w = 35 mm, L = 58 + 33.84 + 46.5 = 138.34 mm
Part 3: Drawing
(Questions 4-5)
Question 4. A cup is to be drawn in a deep drawing
operation. The height of the cup is 75 mm and its inside
diameter = 100 mm. The sheet-metal thickness = 2 mm. If
the blank diameter = 175 mm, determine (a) drawing ratio,
(b) reduction, and (c) thickness-to-diameter ratio. (d) Does
the operation seem feasible?
Solution
(a) DR = Db/Dp = 175/100 = 1.75 (Less than 2, OK)
(b) r = (Db - Dp)/Db = (175 - 100)/175 = 0.429 = 42.9%
(Less than 50%, OK)
(c) t/Db = 2/175 = 0.0114 = 1.14% (Larger than 1, OK)
Remark: Can neglect clearance for calculation.
(d) Feasibility? DR < 2.0, r < 50%, and t/D > 1% → criteria OK
However, the operation is not feasible because the 175 mm
diameter blank size does not provide sufficient metal to draw a 75
mm cup height.
The actual cup height possible with a 175 mm diameter blank can be
determined by comparing volume of blank and volume of cup.
Blank volume = πDb2/4 t = π(175)2/4 x 2 = 48,106 mm2.
Cup volume = πDph t + πDp2/4 t = 100πh x 2 + π(100)2/4 x 2= 200πh +
5000π = 628.32h + 15,708
(approximation, does not take thickness into account).
Set volume of cup = volume of starting blank:
628.32h + 15,708 = 48,106
628.32h = 32,398
h = 51.56 mm. This is less than the specified 75 mm height.
Question 5. A deep drawing operation is performed in which the inside
of the cylindrical cup has a diameter of 8.0 cm and a height = 5.0 cm.
The stock thickness = 0.3 cm, and the starting blank diameter = 15.0 cm.
Punch and die corner radii = 0.4 cm. The metal has a tensile strength =
400 MPa, a yield strength = 180 MPa, and a shear strength of 210 MPa.
Determine
(a) drawing ratio;
(b) reduction;
(c) drawing force; and
(d) blankholder force.
Remark:
Solution
(a) DR = 15/8 = 1.875
(b) r = (Db – Dp)/Db = (15 – 8)/15 = 7/15 = 0.467 = 46.7%
(c) F = πDpt(TS)(Db/Dp - 0.7)
= π(8)(0.3)(400 × 106 × 10–4) (15/8 – 0.7) N
= 354.37 kN
(d) Fh = (0.015Yπ)(Db2 - (Dp + 2.2t + 2Rd)2)
Fh = (0.015(180 × 106 × 10–4)π)(152 – (8 + 2.2 × 0.3 + 2 × 0.4)2) N
Fh = 115 kN