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Drawing is observed in the blank flange as it is being drawn horizontally through the die by the downward action of the punch. A sheet element in the flange is made to elongate in the radial direction and contract in the circumferential direction, the sheet thickness remaining approximately constant Modes of sheet forming are shown in Figure 2.
Figure2 Modes of sheet forming
Stretching is the term usually used to describe the deformation in which an element of sheet material is made to elongate in two perpendicular directions in the sheet plane. A special form of stretching, which is encountered in most forming operations, is plane strain stretching. In this case, a sheet element is made to stretch in one direction only, with no change in dimension in the direction normal to the direction of elongation but a definite change in thickness, that is, thinning.
Bending is the mode of deformation observed when the sheet material is made to go over a die or punch radius, thus suffering a change in orientation. The deformation is an example of plane strain elongation and contraction
A complete press tool for cutting a hole or multi-holes in sheet material at one stroke of the press as classified and standardized by a large manufacturer as a single-station piercing die is shown in Figure3.
Any complete press tool, consisting of a pair( or a combination of pars ) of mating member for producing pressworked (stmped）parts, including all supporting and actuating elements of the tool, is a die. Pressworking terminology commonly defines the female part of any complete press tool as a die.
The guide pins, or posts, are mounted in the lower shoe. The upper shoe contains bushings which slide on the guide pins. The assembly of the lower and upper shoes with guide pins and bushings is a die set. Die sets in many sizes and designs are commercially available. The guide pins are shown in Figure 3.
Figure3 Typical single-station die for piercing hole
1—Lower shoe 2,5—Guide bushings 3—Cavity plate 4—Guid pin 6—Spring-loaded stripper 7—Punch 8—Support plate 9—Punch bushing 10—Fan-shaped block 11—Fixed
plate 12—Punch-holder plate 13—Backing plate 14—Spring 15—Stepping bolts
16—Upper shoe 17—Shank
A punch holder mounted to the upper shoe holds two round punches (male members of the die) which are guided by bushings inserted in the stripper. A sleeve, or quill, encloses one punch to prevent its buckling under pressure from the ram of the press.
After penetration of the work material, the two punches enter the die bushings for a slight distance.
The female member, or die, consists of two die bushings inserted in the die block. Since this press tool punches holes to the diameters required, the diameters of the die bushings are larger than those of the punches by the amount of clearance.
Since the work material stock or workpiece can cling to a punch on the upstroke, it may be necessary to strip the material from the punch. Spring-loaded strippers hold the work material against the die block until the punches are withdrawn from the punched holes. A workpiece to be pierced is commonly held and located in a nest (Figure 2-3) composed of flat plates shaped to encircle the outside part contours. Stock is positioned in dies by pins, blocks, or other types of stops for locating before the downstroke of the ram.
Bending is one of the most common forming operations. We merely have to look at the components in an automobile or an appliance-or at a paper clip or a file cabinet-to appreciate how many parts are shaped by bending. Bending is used not only to form flanges, seams, and corrugations but also to impart stiffness to the part ( by increasing its moment of inertia ).
The terminology used in bending is shown in Figure 4. Note that, in bending, the outer fibers of the material are in tension, while the inner fibers are in compression. Because of the Poisson's ratio, the width of the part (bend length, L) in the outer region is smaller, and in the inner region is larger than the original width. This phenomenon may easily be observed by bending a rectangular rubber eraser.
Minimum bend radii vary for different metals, generally, different annealed metals can be bent to a radius equal to the thickness of the metal without cracking or weakening. As R/T decreases (the ratio of the bend radius to the thickness becomes smaller), the tensile strain at the outer fiber increases, and the material eventually cracks (Figure 5).
Figure 4 Bending terminology
Figure5 Poisson effect
The minimum bend radius for various materials is given in Table 1 and it is usually expressed in terms of the thickness. such as 2 T, 3 T, 4T.
Table 1 Minimum bend radius for various materials at room temperature
Material Soft Aluminum alloys Beryllium copper Brass,low-leaded 0 0 0 Condition Hard 6T 4T 2T