1. Case Study: Emboss and Sheetmetal Distortion
MATE SOLUTIONS TRAINING
Case Study: Emboss and Sheetmetal Distortion

2. Case Study: Emboss and Sheet Distortion
Problem:
When forming, my sheet metal is deformed. How can I reduce or eliminate this?

3. Case Study: Emboss and Sheet Distortion
What is the Root Cause?
Answer:
Material is required to make the form.
Material is pulled and stretched from the surrounding material.
The more material the form requires, the more the sheet will deform.

4. Case Study: Emboss and Sheet Distortion
The material bends without being fully supported. Material is being pulled towards form and deforms surrounding material.

5. Case Study: Emboss and Sheet Distortion
What are some possible solutions?
Flatten sheet later
Add stiffening ribs
Form further from edge
Design part with a break or hem near by
Use thicker material
Increase station size to increase stripping force
Use PowerMax dies to increase stripping force
Use “Upforming” station to increase stripping force
Form Down or Form Down with V-line Gripper
Add a hole on or near the form
Understand what the feature is for. Re-design the part or system to accomplish the same thing another way. There is always more than one way…
Others????

6. Case Study: Emboss and Sheet Distortion
High Spring Forces Applied before forming
FORM DOWN: Use an upper “Punching” assembly.
Using an upper assembly with springs allows the sheet to be pressed flat before forming.

7. Case Study: Emboss and Sheet Distortion
V-Line emboss in the stripper isolates the forming area
FORM DOWN