Chapter 19

Question 1

Define: Stamping

Answer 1

Sheet-metal products from “stamping” presses

Question 2

Define: Cutting

Answer 2

A major sheet metal process used to separate large sheets into smaller pieces, to cut out part perimeters, and to make holes in parts.. Cutting is accomplished by a shearing action between two sharp cutting edges.

Question 3

Define: Plastic Deformation/Rollover

Answer 3

When the upper cutting edge (the punch) begins to push into the work.

Rollover is the top of the curt surface and corresponds to the depression made by the punch in the work prior to cutting

Question 4

Define: Penetration/Burnish

Answer 4

As the punch moves compresses the sheet and cuts into the metal. This penetration zone is generally about one-third the thickness of the sheet..

Burnish is just below the rollover and is a relatively smooth region, resulting from penetration of the punch into the work before fracture

Question 5

Define: Fracture

Answer 5

As the punch continues to travel into the work, “fracture” is initiated int he work at the two cutting edges. IF clearance is correct, the two fracture lines meet, resulting in a clean separation of the work into two pieces.

Question 6

Define: Burr

Answer 6

A sharp corner on the edge caused by elongation of the metal during final separation of the two pieces

Question 7

Define: Shearing

Answer 7

Sheet-metal operations along a straight line between two cutting edges; typically used to cut large sheets into smaller sections for subsequent press-working operations

Machine=power shears/squaring shears

Question 8

Define: Blanking vs Punching

Answer 8

Blanking- Involves cutting of the sheet metal along a closed outline in a single step to separate the piece from the surrounding stock (ex. square piece)

Punching- (similar to blanking) It produces a hole in a piece with a separate circular hole portion that is scrap, called a slug

Question 9

Define: Clearance

Answer 9

The clearance “c” in a shearing operation is the distance between the punch and the die. Typically, c = 4-6% of sheet metal thickness (t).

c = Ac * t, where Ac (clearance allowance) is determined by metal.

Question 10

Define: Cutoff vs. Parting

Answer 10

Cutoff: is a shearing operation in which blanks are separated from a sheet-metal strip by cutting the opposite sides of the part in sequence

Parting: involves cutting a sheet metal strip by a punch with two cutting edges that match the opposite sides of the blank

Question 11

Define: Perforating

Answer 11

Involves the simultaneous punching of a pattern of holes in sheet metal. The hole pattern is usually for decorative purpose, or to allow passage of light or fluid.

Question 12

Define: Notching vs. Semi-Notching

Answer 12

Notching: Involves cutting out a portion of metal from the side of the sheet or strip

Semi-notching: removes a portion of metal from the interior of the sheet and creates part of the blank outline but creating a cutoff line into the interior.

Question 13

Define: Bending

Answer 13

In sheet-metal work is defined as the straining of the metal around a straight axis. The metal on the inside of the neutral plain is compressed, while the metal on the outside of the neutral plane is stretched

Question 14

Define: Edge vs. V-bending

Answer 14

Edge Bending: Involves cantilever loading of the sheet metal, while a force is applied to hold the base of the part against the die (high production operations)

V-Bending: Sheet metal bent between a V-shaped punch and die (low production operations)

Question 15

Define: Bend Allowance

Answer 15

The estimated amount of stretching that occurs during bending.

Allowance = 2 * pi * (angle/360) * (R + K * t)

Question 16

Define: Springback

Answer 16

When bending pressure is removed at the end of the deformation operation, elastic energy remains in the the bent part, causing it to recover partially toward its original shape

Question 17

Define: Flanging

Answer 17

Is a bending operation in which the edge of a sheet metal part is bent at a 90 degree angle to form a rim or flange

Question 18

Define: Hemming

Answer 18

Involves bending the edge of the sheet over on itself in more than one bending step (done to eliminate the sharp edge on the piece, increase stiffness, and improve appearance

Question 19

Define: Seaming

Answer 19

A related operation in which two sheet-metal edges are assembled together in two, hemmed regions.

Question 20

Define: Beading/Curling

Answer 20

Forms the edges of the part into a roll or curl. Done for the purpose of safety, strength, and aesthetics.

Question 21

Define: Drawing

Answer 21

A Sheet metal forming operation performed by placing a piece of sheet metal over a die cavity and then pushing the metal into the opening with a punch. The blank must usually be held down flat against the die by a blankholder.

Question 22

Define: Thinning

Answer 22

Due to the downward motion of the punch in a continuation of the metal flow caused by drawing, the walls of the cylinder are thinned

Question 23

Define: Drawing Ratio

Answer 23

(or DR) is the ratio of blank diameter (Db) to punch diameter (Dp)

DR = Db/Dp

Question 24

Define: Blanketholder

Answer 24

The piece that holds the blank flat against the die. The force applied by the blankholder is called the “holding force”

Question 25

Define: Wrinkling (in flange or wall)

Answer 25

Defect of drawing in which a series of ridges form radially in the undrawn flange of the work part or in the vertical wall. These are a result of compressive buckling

Question 26

Define: Ironing

Answer 26

Used to make cylindrical cup more uniform in wall thickness by drawing into a smaller circumference diameter after drawing into the original.

Question 27

Define: Embossing

Answer 27

Used to create indentation in the sheet such as raised (or indented) lettering or strengthening of ribs. Similar to coining except that embossing dies possess matching cavity contours.

Question 28

Define: Lancing

Answer 28

A combined cutting and bending or cutting and forming operation performed in one step to partially separate the metal from the sheet

Question 29

Define: Compound vs. Progressive Die

Answer 29

Compound: Performs two operations at a single station, such as blanking and punching, or blanking and drawing

Progressive: Performs two or more operations on a sheet metal coil at two or more stations with each press stroke. The part is fabricated progressively

Question 30

Define: Roll Bending

Answer 30

Is an operation in which (usually) large sheet-metal or plate-metal parts are formed into curved sections by means of rolls.

Question 31

Define: Roll Forming

Answer 31

(or Contour Roll Forming) is a continuous bending process in which opposing rolls are used to produce long sections of formed shapes from coil and strip stock.

Question 32

Define: Spinning

Answer 32

Bends metal around a moving circular axis to conform to the outside surface of the axisymmetric mandrel.

Question 33

Define: Tube Bending

Answer 33

When tube is bent, the wall on the inside of the bend is in compression and the wall at the outside is in tension. These conditions create thinning and elongation of the outer wall and thickening and shortening of the inner wall. Minimum Bend radius R that the tube can be bent is about 1.5 times larger the diameter D.

Stretch, Draw, and Compression bending are all means of tube bending