DEDICATION
To my children and
and
to my wife, Anka
TABLE OF CONTENTS
Preface List of Tables
Introduction Basic Characteristics
of Sheet-Metal Forming Processes Categories of Sheet-Metal Forming Processes
Characteristics of Sheet-Metal Parts and Their Technological Properties
PART I THEORETICAL FUNDAMENTALS
Chapter 1 1.1
1.2 1.3
1.3.1 1.3.2
1.3.3 1.4
Chapter 2 2.1
2.2 2.3
2.4
The Structure of Metals Introduction
The Crystal Structure of Metals Deformation and the Strength
of Crystals Imperfections in the Crystal Structure
of Metals Grain Sizes and Boundaries
Strain Hardening Recovery and Recrystalization
Mechanical Behavior of Materials Introduction
Stress Strain Curves Ductility
True Stress and True Strain
PART
MANUFACTURING PROCESSES Chapter 3
3.1 3.2
3.2.1 3.2.2
3.3.3
Chapter 4 4.1
4.2 4.3
4.3.1
Shearing Process Mechanics of Shearing
Shearing Forces Shearing with Straight Parallel Cutters
Shearing with Straight Inclined Cutters Shearing with Rotary Cutters
and Punching
Blanking and Punching Mechanism Blanking and Punching Clearances
Punch Force Punch and Die with Parallel Cut Edges
xiii xv
xvii xvii
xvii
xviii
1 3
3 3
6 7
9
10 11
13
13 16
18 19
21 23
23 23
24 25
27
29 29
31 33
33
vii
viii
Table of Contents
4.3.2 4.4
4.4.1 4.4.2
4.4.3 4.4.4
4.5 4.5.1
4.5.2
Chapter
5 5.1
5.2 5.3
5.3.1
5.3.2 5.4
5.4.1
5.4.2 5.4.3
5.4.4 5.4.5
5.5 5.5.1
5.5.2 5.6
5.7 5.8
Chapter
6 6.1
6.2 6.2.1
6.3 6.3.1
6.3.2 6.4
6.5 6.5.1
6.5.2 6.6
Punch and Die with Bevel-cut Edges Material Economy
Scrap Strip Layouts Altering the Design of the Workpiece
Multi-line Layout Utilizing Scrap from One Piece as Material for Another Piece
Shaving Shaving a Punched Workpiece
Shaving a Blanked Workpiece
Bending Introduction
Mechanics of Bending Moment of Bending
Moment of Bending in Elastic-Plastic Domain
The Moment of Bending in the Purely Plastic Domain Bending Forces
Force for a U-die Forces for a Wiping Die
Forces for a V-die Curling
Three-Roll Forming Bend Radius
Minimum Bend Radius Maximum Bend Radius
Bend Allowance
Springback Clearance
Deep Drawing Introduction
Mechanics of Deep Drawing Deep Drawability
Forces First Drawing Operation
Subsequent Drawing Operations Blank Calculations for Symmetrical Shells
Determining Shape of Blank for
Shells Rectangular Shells
Square Shells Drawing Practice
34 35
35 37
37
38 39
39 43
45
45 45
46
49 50
51 51
52 53
55 56
57 57
59 60
64 67
69
69 70
72
74 74
75 76
78 78
81
82
Table of Contents
6.6.1 6.6.2
Chapter 7 7.1
7.2 7.3
7.4 7.5
7.6 7.6.1
Defects During Deep Drawing Lubrication in Drawing
Various Forming Processes
Stretch Forming Nosing
Expanding Dimpling
Spinning Flexible Die Forming
Force in Die Forming
PART 111 DIE DESIGN Chapter 8
8.1 8.2
Chapter 9 9.1
9.2 9.2.1
9.2.2 9.2.3
9.2.4
9.3 9.3.1
9.3.2 9.3.3
