SHEARING
• Shearing - cutting operation used to remove a
blank of required dimensions from a large sheet
• cut edges are neither smooth nor perpendicular to
the plane of the sheet
• The clearance between the punch and the die - 2 to
10% of the sheet thickness
Straight line shear
• Shearing may also be done between a punch and
die that include punching, blanking, piercing,
notching, trimming, and nibbling.
Punching
• Punching - process in which the punch removes a
portion of material from the larger piece or a strip
of sheet metal.
• The small removed piece is discarded
Blanking
• Blanking - process in which the punch removes a
portion of material from the larger piece or a strip
of sheet metal.
• The small removed piece is the useful part and the
rest is scrap
Die size = Blank size, and the punch is made smaller, by considering the
clearance
2 degree of angular clearance is sufficient. The height of cutting land of
about 3 mm is generally sufficient.
Stripper
• Thick material,hole at centre, close punches – more Fstripper
Fstripper = 2.5% to 20% of Fpunch
• The maximum force, P required to be exerted by
the punch to shear out a blank from the sheet can
be estimated as
P = t. L.τ
where t is the sheet thickness, L is the total length
sheared (such as the perimeter of hole), and τ
is the shear strength of the sheet material
Clearance
c = At,
where,
A is clearance allowance
t is sheet thickness.
The clearance allowance A is taken to be 0.075 for
most of the steels and 0.045 for aluminium alloys.
Blanking
Die size = blank size
Punch size = blank size – 2 x clearance
Clearance = k . t . t
where t is the shear strength of material,
t is the thickness of sheet metal stock, and
k is a constant whose value may be taken as 0.003
Punching
Punch size = blank size
Die size = blank size + 2 x clearance
Clearance = k . t . t
A circular blank of 30 mm diameter is to be cut from
2 mm thick 0.1 C steel sheet. Determine the die and
punch sizes. Also estimate the punch force required.
Assume the following for the steel : Tensile strength:
410 MPa ; shear strength : 310 MPa
For cutting a blank, die size = blank size
\ Die size = 30mm
Clearance = 0.003 x t x t = 0.003 x 2 x 310
= 1.86 mm
Punch size = blank size – 2 clearance
= 30 – (2 x 1.86) = 26.28 mm
Punch force needed = L. t. t = p x 30 x 2 x 310
= 58.5 kN
Piercing
Piercing is process in which punch operation cuts a
hole / material by tearing operation from a final
piece of sheet metal.
Notching, Trimming, Nibbling
Problem 2:
Determine the die and punch sizes for blanking a
circular disc of 20 mm diameter from a C20 steel
whose thickness is 1.5 mm. The Shear strength of
C20 steel is 294 Mpa.
Blanking operation:
Die size = blank size
Punch size = blank size – (2 x clearance)
Die size = blank size = 20 mm
Clearance = a.t = 0.075 x 20 = 1.5 mm
Punch size = 20 – (2x1.5) = 17 mm
What if piercing operation????
Piercing operation
Punch size = blank size
Die size = blank size + (2 x clearance)
Punch size = blank size = 20 mm
Die size = 20 + (2 x 1.5) = 23 mm
What will be the Punching and
stripper force???
Fpunching = P.t.Ʈ,
= πd.t.Ʈ
= π x 20 x 1.5 x 294
= 27.7 kN
Fstripper = 5% of Fpunch (assuming)
= 0.05 x 27.7
= 1.39 kN
Punch radius (r) = 4 to 10 t
Die radius (R) = 4 t normal
= 6 to 8 t (when blank holder is used)
= 0.8 (D-d) t
Clearanace = 7 to 20% t
Drawing force = πdtY[(D/d)-C]
Y – Yield strength (Mpa)
C – constant to cover friction and bending (0.6 to 0.7)
Deep Drawing
• When cup height > 0.5 diameter
Ironing
• Ironing of sheet metal is a manufacturing process
that is mostly used to achieve a uniform wall
thickness in deep drawings
• A punch and die pushes the part through a
clearance that will act to reduce the entire wall
thickness to a certain value.
• While reducing the entire wall thickness, ironing
will cause the part to lengthen.
• The percentage reduction in thickness for an
ironing operation is usually 40% to 60%.
