‫المحاضرة الثامنة عشر‬

Advantages of rubber forming process

 Low tooling cost

 Form block can be made of wood, plastic,
or other materials that are easy to shape
 Rubber pad can be used with different
form blocks
 Process attractive in small quantity
production
 Types of press

1- Mechanical Stamping Press

Mechanism of mechanical press
The total energy (W) supplied during the
stroke of a press is given by
2- Gap frame hydraulic press
3- Straight-sided frame hydraulic press
 Hydraulic presses
 Longer ram stroke than mechanical
types
 Slower than mechanical drives
 Uses in deep drawing process
 Mechanical presses
 High forces at bottom of stroke
 uses in blanking and punching process
 Operations Not Performed on Presses

 Stretch forming
 Roll bending
 Spinning
 High-energy-rate forming processes.
 Stretch Forming

Sheet metal is stretched and

simultaneously bent to achieve shape
change
 Force Required in Stretch Forming

F  LtYf
where F = stretching force; L = length of
sheet in direction perpendicular to
stretching; t = instantaneous stock
thickness; and Yf = flow stress of work
metal
 Stretch Forming

. Stages of Stretch forming by hydraulic press.

 Roll Bending
metal sheets and plates are formed into
curved sections using Three rolls

Roll bending.
 Force system in roll bending

bending position
Force system in roll bending
F roll bending force

N Reaction force at the contact point

of the lower rolls
l Projected contact length at
contact angle
t Sheet thickness
L Distance between center of
lower rolls
α Contact angle between upper roll
and sheet metal
d roll diameter
 Roll Forming

Continuous bending process in which opposing

rolls produce long sections of formed shapes from
coil or strip stock

Figure 20.41 Roll

forming of a
continuous
channel section:
(1) straight rolls,
(2) partial form,
(3) final form.
 Spinning

Metal forming process in which an axially

symmetric part is gradually shaped
over a rotating mandrel using a
rounded tool or roller
 Three types:
1. Conventional spinning
2. Shear spinning
3. Tube spinning
 1- Conventional Spinning

Figure 20.42 Conventional spinning: (1) setup at start of process;

(2) during spinning; and (3) completion of process.
Spinning
 cones dishes cups

Concave Hemi-spherical Curved

shape shape shape
 Sheer Spinning
In shear spinning, the part is formed over
the mandrel by a shear deformation
process in which the outside diameter
remains constant and the wall thickness is
therefore reduced,
The process has been applied in the
aerospace industry to form large parts such
as rocket nose cones.
 Sheer Spinning

FIGURE 20.43 Shear spinning: (1) setup and (2) completion of process
 Tube Spinning
Tube spinning is used to reduce the wall thickness and
increase the length of a tube by means of a roller
applied to the work over a cylindrical mandrel,

Tube spinning: (a) external; (b) internal.

 Tube Spinning

Forward backward
High-Energy-Rate Forming (HERF)
Processes to form metals using large amounts of
energy over a very short time ( very high
deformation rate )
 HERF processes include:
 Explosive forming
 Electrohydraulic forming
 Electromagnetic forming
 Explosive Forming
Use of explosive charge to form sheet (or plate)
metal into a die cavity
 Explosive charge causes a shock wave whose
energy is transmitted to force part into cavity
 Applications: large parts, typical of aerospace
industry
Explosive Forming
‫النهاية‬
 Electrohydraulic forming

Electrohydraulic forming is a type of metal forming in which an

electric arc discharge in liquid is used to convert electrical
energy to mechanical energy and change the shape of the
workpiece
Electrohydraulic forming
Electrohydraulic forming
 Electrohydraulic forming
A sudden electrical discharge in the form of sparks is
produced between electrodes and this discharge produces a
shock wave in the water medium. This shock wave deforms
the work plate into the die . The characteristics of this
process are similar to those of explosive forming. The major
difference, however, is that a chemical explosive is replaced
by a capacitor bank, which stores the electrical energy. The
capacitor is charged through a charging circuit. When the
switch is closed, a spark is produced between electrodes
and a shock wave or pressure pulse is created.
 Process Characteristics:
i) Stand off distance: It must be optimum.
ii) Capacitor used: The energy of the pressure pulse
depends on the size of capacitor.
iii) Transfer medium: Usually water is used.
iv) Vacuum: the die cavity must be evacuated to prevent
adiabatic heating of the work due to a sudden
compression of air.
v) Material properties with regard to the application of
high rates of strain.
 Advantages:
i) Better control of the pressure pulse as source
of energy is electrical- which can be easily
controlled.
ii) Safer in handling than the explosive materials.
iii) More suitable if the work size is small to
medium.
iv) Thin plates can be formed with smaller
amounts of energy.
v) The process does not depend on the electrical
properties of the work material.
 Limitations:
i) Suitable only for smaller parts Limitations
ii) Need for vacuum makes the equipment more
complicated.

Applications:
They include smaller radar dish, cone and other
shapes in thinner and small works.
Electromagnetic Forming
 Electromagnetic Forming

The electrical energy stored in a capacitor

bank is used to produce opposing magnetic
fields around a tubular work piece,
surrounded by current carrying coils.
The coil is firmly held and hence the work
piece deformed into the die cavity due to
magnetic force.
 Process details/ Steps:
i) The electrical energy is stored in the capacitor
bank
ii) The tubular work piece is mounted on a mandrel
having the die cavity to produce shape on the tube.
iii) A primary coil is placed around the tube and
mandrel assembly.
iv) When the switch is closed, the energy is
discharged through the coil
v) The coil produces a varying magnetic field
around it.
vi) In the tube a secondary current is induced, which
creates its own magnetic field in the opposite
direction.
vii) The directions of these two magnetic fields
oppose one another and hence the rigidly held
coil repels the work into the die cavity.
 Process parameters:

i) Work piece size

ii) Electrical conductivity of the work material.
iii) Size of the capacitor bank
iv) The strength of the current, which decides the
strength of the magnetic field and the force
applied.
v) Insulation on the coil.
vi) Rigidity of the coil
 Advantages

i) Suitable for small tubes

ii) Operations like forming, bending can be easily done.
iii) Electrical energy applied can be precisely controlled
and hence the process is accurately controlled.
iv) The process is safer compared to explosive forming.
v) Wide range of applications.
 Limitations:

i) Applicable only for electrically conducting materials.

ii) Not suitable for large work pieces.
iii) Rigid clamping of primary coil is critical.
iv) Shorter life of the coil due to large forces acting on it.
 Applications:

i) corrugated shapes
ii) Bending of tubes into complex shapes
iii) Bulging of thin tubes.
Internal electro-magnetic forming