Sheet Metal Forming Processes and Die Design

By: Vukota Boljanovic

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Hardcover | 23 July 2004

At a Glance

Hardcover
219 Pages

Dimensions(cm)
25.4 x 20.32 x 1.91

New Edition

Published: 1st April 2014

Hardcover

$195.25

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Emphasizes the influence of materials as an aid to understanding manufacturing processes and operations.
Features the essential mathematical formulas and calculations needed for
various die operations and performance evaluation.
Shows the comparative advantages and liabilities for each manufacturing process and operation.
Offers a complete picture of the knowledge and skills needed for the effective design of dies for sheet-metal forming processes highlighted with illustrative examples.
Provides properties and typical applications of selected tool and die materials for various die parts.

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You Can Find This Book In

Non-Fiction Handicrafts, Decorative Arts & Crafts Decorative Wood & Metalwork Kids & Children's Books Educational Material Technology Educational Material Engineering & Technology Industrial Chemistry & Manufacturing Technologies Metals Technology & Metallurgy Mechanical Engineering & Materials Production & Industrial Engineering Science

Technology in General Engineering in General

Preface	p. xiii
List of Tables	p. xv
Introduction	p. xvii
Basic Characteristics of Sheet-Metal Forming Processes	p. xvii
Categories of Sheet-Metal Forming Processes	p. xvii
Characteristics of Sheet-Metal Parts and Their Technological Properties	p. xviii
Theoretical Fundamentals	p. 1
The Structure of Metals	p. 3
Introduction	p. 3
The Crystal Structure of Metals	p. 3
Deformation and the Strength of Crystals	p. 6
Imperfections in the Crystal Structure of Metals	p. 7
Grain Sizes and Boundaries	p. 9
Strain Hardening	p. 10
Recovery and Recrystalization	p. 11
Mechanical Behavior of Materials	p. 13
Introduction	p. 13
Stress / Strain Curves	p. 16
Ductility	p. 18
True Stress and True Strain	p. 19
Manufacturing Processes	p. 21
Shearing Process	p. 23
Mechanics of Shearing	p. 23
Shearing Forces	p. 23
Shearing with Straight Parallel Cutters	p. 24
Shearing with Straight Inclined Cutters	p. 25
Shearing with Rotary Cutters	p. 27
Blanking and Punching	p. 29
Blanking and Punching Mechanism	p. 29
Blanking and Punching Clearances	p. 31
Punch Force	p. 33
Punch and Die with Parallel Cut Edges	p. 33
Punch and Die with Bevel-cut Edges	p. 34
Material Economy	p. 35
Scrap Strip Layouts	p. 35
Altering the Design of the Workpiece	p. 37
Multi-line Layout	p. 37
Utilizing Scrap from One Piece as Material for Another Piece	p. 38
Shaving	p. 39
Shaving a Punched Workpiece	p. 39
Shaving a Blanked Workpiece	p. 43
Bending	p. 45
Introduction	p. 45
Mechanics of Bending	p. 45
Moment of Bending	p. 46
Moment of Bending in Elastic-Plastic Domain	p. 49
The Moment of Bending in the Purely Plastic Domain	p. 50
Bending Forces	p. 51
Force for a U-die	p. 51
Forces for a Wiping Die	p. 52
Forces for a V-die	p. 53
Curling	p. 55
Three-Roll Forming	p. 56
Bend Radius	p. 57
Minimum Bend Radius	p. 57
Maximum Bend Radius	p. 59
Bend Allowance	p. 60
Springback	p. 64
Clearance	p. 67
Deep Drawing	p. 69
Introduction	p. 69
Mechanics of Deep Drawing	p. 70
Deep Drawability	p. 72
Forces	p. 74
First Drawing Operation	p. 74
Subsequent Drawing Operations	p. 75
Blank Calculations for Symmetrical Shells	p. 76
Determining Shape of Blank for Nonsymmetrical Shells	p. 78
Rectangular Shells	p. 78
Square Shells	p. 81
Drawing Practice	p. 82
Defects During Deep Drawing	p. 82
Lubrication in Drawing	p. 82
Various Forming Processes	p. 85
Stretch Forming	p. 85
Nosing	p. 87
Expanding	p. 92
Dimpling	p. 94
Spinning	p. 96
Flexible Die Forming	p. 99
Force in Die Forming	p. 99
Die Design	p. 101
Basic Die Classifications and Components	p. 103
Die Classifications	p. 103
Basic Die Components	p. 105
Blanking and Punching Dies	p. 109
Introduction	p. 109
Die Blocks	p. 110
Die Opening Profile	p. 110
Fastening to the Die Shoe	p. 111
Sectioned Die	p. 112
Calculation of Die Block Dimensions	p. 113
Punches	p. 116
Punch Face Geometry	p. 116
Methods for Assembling Punches	p. 116
Punch Calculations	p. 118
Stripper Plates	p. 120
Stripper Force	p. 120
Stripper Design	p. 121
Die Components for Guiding and Stopping	p. 124
Stock Guides and Guide Rails	p. 124
Die Stops and French Notch Punch	p. 126
Positioning the Individual Blank	p. 127
Pilots	p. 128
Center of Die Pressure	p. 129
Examples of Couting Die Designs	p. 131
Bending Dies	p. 135
Introduction	p. 135
Simple Die Designs	p. 135
U-Profile Bend Dies	p. 135
V-profile Bend Dies	p. 137
Universal Bending Dies	p. 138
Dies of Complex Design	p. 139
Closing Profile Dies	p. 139
Special Bending Dies	p. 139
Curling and Hinge Dies	p. 141
Tube-forming Dies	p. 142
Multiple-bend Dies	p. 144
Combination Dies	p. 144
Progressive Dies	p. 145
Deep Drawing Dies	p. 147
Introduction	p. 147
Draw Rings	p. 147
Draw Rings with Corner Radius	p. 147
Draw Rings with Conical Profile	p. 149
Clearances and Tolerances	p. 151
Calculation of the Dimensions of the Punch and Die	p. 151
Blank Holders	p. 154
Blank Holders	p. 154
Blank Holder Pressure	p. 155
Blank Holder Force	p. 155
Draw Beads	p. 156
Single-operation Dies	p. 158
Multi-operation Dies	p. 160
Progressive Dies	p. 160
Drawing Dies for Pieces of Spherical and Parabolic Shape	p. 162
Ironing Dies	p. 164
Various Forming Dies	p. 167
Nosing Dies	p. 167
Expanding and Bulging Dies	p. 170
Expanding Dies	p. 170
Bulging Dies	p. 171
Flanging Dies	p. 172
Tool and Die Materials	p. 175
Introduction	p. 175
Carbon and Alloy Steels	p. 175
Designations for Carbon and Alloy Steels	p. 176
Effects of Various Alloy Elements in Steels	p. 176
Carbon Steels	p. 176
Alloy Steels	p. 177
Machinability of Steels	p. 177
Mechanical Properties of Steels	p. 178
Applications of Carbon and Alloy Steels	p. 179
Tool and Die Steels	p. 179
Designation and Classification of Tool and Die Steels	p. 179
Cold Work Tool and Die Steels	p. 181
Nonferrous Metals	p. 182
Nonmetallic Materials	p. 183
Blank Diameter of Drawn Shells	p. 185
Metric System Tolerances on Linear Dimensions	p. 189
Miscellaneous Information	p. 199
Glossary	p. 209
Bibliography	p. 215
Index	p. 217
Table of Contents provided by Rittenhouse. All Rights Reserved.

Sheet Metal Forming Processes and Die Design

At a Glance

New Edition

Hardcover

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How to return your order

Defective items

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