BENDING

OVER VIEW
Bending operation is carried out in the plastic zone. While bending outer layer experiences increase in length and the radius portion will have more hardness (ie more than 50% compared to other areas.) If bending has to take place severely the hardness of the material shouldn't be more than 55 HRB. However materials having hardness till 70-75 HRB can be bend to L shape.

STRAIN FACTOR
Strain at yield point is 0.2% While bending three types of strains are occurring in the material a) Engineering starin b) true strain c) linear strain The sum of all the three strains should be zero

FORCES ACTING ON MATERIAL

While bending there are two types of forces acting on the material a) Compressive force b) Tensile force In compression the width get increased and length decreases. In tension length is getting increased and width is decreasing. The resistance of the material in compression is more.

 Bending should always be on a straight line. While bending the burr should face always the punch side. More the bend angle more the bend severity Lower the bend radius more the bend severity. Before fracture steel can be stretched to 28%.At that time thickness & width reduces. But volume remains constant.

BLANK DEVELOPMENT
1) By CORRECTION FACTOR 2) By THUMB RULE 3) By FORMULAE AND TABLES.

FORMULA FOR CENTRE FIBRE N.F=Pi/180(Ri+s/2)

NTTF METHOD N.F= A+B+Pi /180(Ri+S/2*)

Ri

0.1

0.2

0.3

0.4

0.5

0.8

1.0

1.5

2.0

3.0

4.0

5.0

10.0

0.23 0.29 0.32 0.35 0.37 0.4

0.41 0.44 0.45 0.46 0.47 0.48 0.50

SCHULLER METHOD If opening angle is 0 to 165 then l= a+b+v If opening angle is from 165 to 180 then l= a+b

BENDING FORCE IN V- BENDING

Bending force sheet thickness ultimate tensile strength width of die 1/ opening width Width of die opening is generally taken as 10 times of sheet thickness.

 If bend radius =0 to 90 v=pi (180- /180) (ri+s/2.kr)-2(ri+s)

If >90 to 165
v=pi(180 - /180)+r+s/2.kr)-2(r+s)-tan(180 - /2)

With correction factor k -k=1 for r/s > 5 &

DRAWING
In bending stress creation is in a straight line. But in drawing total 3D dimensional deformation is taking place. In drawing blank should be held properly so that the component wont buckle. So blank holder is a must in drawing tools. All the three planes experiences stress in case of drawing.

 Circumferential compression and radial tension is the other peculiarity of drawing. Angular changes will be greater in the outer layer of the shell. The bottom of the shell remains unchanged.

MAJOR FACTORS IN DRAWING

Punch radius Die corner radius Clearance(7-12% of s) Blank holder pressure Speed of the punch Strain hardening Air escape during draw

BLANK DEVELOPMENT
BLANK DIA D=d+4dh D=area of the cup