UNIT IV SHEET METAL PROCESSES

Sheet metal characteristics shearing,

bending and drawing operations Stretch
forming operations Formability of sheet
metal Test methods special forming
processes-Working
principle
and
applications Hydro forming Rubber pad
forming Metal spinning Introduction of
Explosive forming, magnetic pulse forming,
peen forming, Super plastic forming Micro
forming.

Sheet Metal Forming

A large variety of industrial components
is manufactured by processing sheet
metal into finished parts.
Common sheet metal operations are
carried on sheets from 3 to 6mm thick.
Applications
Automobile
Aircraft bodies
Kitchen ware
Furniture items
Mechanical toys etc.

Sheet metal processes

Processes involving shear stress
Processes involving compressive
stresses
Processes involving tensile stresses
Processes involving both tensile and
compressive stresses

Metal characteristics affecting sheet

metal processing

Elongation
Anisotropy
Grain size
Spring back
Quality of sheared edges
Residual stresses
Surface condition of the sheets.

Shearing operations
Blanking
Punching

https://www.youtube.com/watch?v=VMu7_W0QE3Y
https://www.youtube.com/watch?v=Rn31IEOKgQ8

Piercing

Trimming

Shaving

Notching
https://www.youtube.com/watch?v=
t7xuH0D_o_c

Drawing operations
Drawing

https://www.youtube.com/w
atch?v=ejJ6Uqs5grU
It is the process of producing thin
walled cup from flat sheet metal
blanks.
Drawing operations
Deep Drawing

https://www.youtube.com/w
atch?v=y4N2iusS-30
It is the process the depth of the
drawn part exceeds its diameter to
prevent excess wrinkling of the
edges. Such operation are called
deep drawing.

Ironing

Ironing

Ironing is the process of smoothing

and thinning the wall of a shell or cup
(cold or hot) by forcing the shell
through a die with a punch.

Redrawing

https://www.youtube.com/watch?v=wjvzl912Pp0

Bending operation

https://www.youtube.com/
watch?v=x1rpy7GOPjQ

Bending is a manufacturing process

that produces a V-shape, U-shape, or
channel shape along a straight axis
in ductile materials, most commonly
sheet metal. Commonly used
equipment include box and pan
brakes, brake presses, and other
specialized machine presses

Curling or wiring

Roll Bend
https://www.youtube.com/watch?v=
2Tif0WT7PZ8

Nomenclature of Bending

Stretch forming operations

https://www.youtube.com/
watch?v=91TX4hSUDpk
Stretch forming is a metal forming process in which a piece of sheet metal is
stretched and bent simultaneously over a die in order to form large contoured parts.
Stretch forming is performed on a stretch press, in which a piece of sheet metal is
securely gripped along its edges by gripping jaws. The gripping jaws are each
attached to a carriage that is pulled by pneumatic or hydraulic force to stretch the
sheet. The tooling used in this process is a stretch form block, called a form die,
which is a solid contoured piece against which the sheet metal will be pressed.

Formability of sheet metal

Formability Tests
Cupping test
Tests based on tensile Test
Simulative drawing Tests
Erichsen Test
Olsen Test
Swift Test
Fukui Test
Full scale forming Test (Forming Limit
Diagram)

Full scale forming Test (Forming Limit

Diagram)

Embossing

Hydro forming

https://www.youtube.com/
watch?v=XUMs3cWBlks
Hydroforming is a cost-effective way of shaping ductile metals such as aluminium,
brass, low alloy steels, stainless steel into lightweight, structurally stiff and strong
pieces. One of the largest applications of hydroforming is the automotive industry,
which makes use of the complex shapes possible by hydroforming to produce
stronger, lighter, and more rigid unibody structures for vehicles. This technique is
particularly popular with the high-end sports car industry and is also frequently
employed in the shaping of aluminium tubes for bicycle frames.

Rubber Pad Forming

https://www.youtube.com/w
atch?v=JQi1hlYbBGQ

Rubber pad forming (RPF) is a

metalworking process where sheet
metal is pressed between a die and a
rubber block, made of polyurethane.
Under pressure, the rubber and sheet
metal are driven into the die and
conform to its shape, forming the
part. The rubber pads can have a
general purpose shape, like a
membrane. Alternatively, they can

Metal Spinning

https://www.youtube.com/w
atch?v=um-biLfru-c

Metal spinning, also known as spin

forming or spinning or metal turning
most commonly, is a metalworking
process by which a disc or tube of
metal is rotated at high speed and
formed into an axially symmetric
part.

Explosive forming(or)High energy

rate forming

https://www.youtube.com/
watch?v=OGNrvmaxe8c
Explosive
forming
is
a
metalworking
technique in which an explosive charge is
used instead of a punch or press. It can be
used on materials for which a press setup
would be prohibitively large or require an
unreasonably high pressure, and is generally
much cheaper than building a large enough
and sufficiently high-pressure press; on the
other hand, it is unavoidably a batch process,
producing one product at a time and with a
long setup time

Electromagnetic pulse forming or

(High energy rate forming)

https://www.youtube.com/
watch?v=NrDe48_pxpY

Electromagnetic forming (EM forming or

magneforming) is a type of high velocity,
cold forming process for electrically
conductive metals, most commonly
copper and aluminium. The work piece is
reshaped by high intensity pulsed
magnetic fields that induce a current in
the work piece and a corresponding
repulsive magnetic field, rapidly repelling
portions of the work piece.

Peen forming

https://www.youtube.com/
watch?v=AgPsxoZnEa0

Peen forming is a die-less cold

forming process performed at room
temperature with procedure of shot
peening. The peen forming process is
ideal for forming large panel shapes
where the bend radii are reasonably
large without abrupt changes in
contour.

Super Plastic forming

https://www.youtube.com/
watch?v=KPFAoLmJ5og
To begin with, the material must have

an
ultra-fine grain size. It is then heated up to
promote super plasticity. For titanium alloys*
Ti 6Al 4V and some stainless steels* this is
around 900 C (1,650 F) and for aluminium
alloys it is between 450520 C. In this state
the material is not very strong so processes
that are usually used on plastics can be
applied, such as: thermoforming, blow
forming, and vacuum forming; it may also be
deep drawn

Micro forming

Micro forming is defined as the

forming of pieces whose total
dimensions are located below 1mm3,
and which are formed from metal
sheets of 10 to 300 microns of
thickness.