Sheet metal forming process

Unit 4
 Introduction

 Sheet metal is simply metal formed into thin

and flat pieces. It is one of the fundamental forms
used in metalworking, and can be cut and bent into
a variety of different shapes. Countless everyday
objects are constructed of the material.
Thicknesses can vary significantly, although
extremely thin thicknesses are considered foil or
leaf, and pieces thicker than 6 mm (0.25 in) are
considered plate.
 Sheet metal processing

 The raw material for sheet metal

manufacturing processes is the output of the
rolling process. Typically, sheets of metal are
sold as flat, rectangular sheets of standard size.
If the sheets are thin and very long, they may
be in the form of rolls. Therefore the first step
in any sheet metal process is to cut the correct
shape and sized ‘blank’ from larger sheet.
Spring Back
 Shearing Stress

• Blanking
• Piercing
• Nibbling
• Notching
• Trimming
• Shaving
 Shearing

 Shearing is a sheet metal cutting operation

along a straight line between two cut-ting
edges by means of a power shear.
Angular clearance
 Blanking and punching

 Blanking and punching are similar sheet metal cutting

operations that involve cutting the sheet metal along a
closed outline. If the part that is cut out is the desired
product, the operation is called blanking and the product
is called blank. If the remaining stock is the desired part,
the operation is called punching. Both operations are
illustrated on the example of producing a washer
Progressive die
Bending
Nibbling
 Tension and Compression
 Drawing
 Deep Drawing
 Spinning
 Bending
 Forming
Drawing
Deep Drawing
Deep Drawing
Deep Drawing Product
 To avoid taper problem further process is
required
Spinning
Bending
Embossing
Coining
Forming
 High Energy Rate Forming(HERF)
 For new temperature resistant
• High strength metals
• Require short production runs
• Not possible by conventional methods
Classification
1. High Energy rate forming process
2. High velocity forming process
 High Energy rate forming process

 Energy required for processing will be

obtained in a very short time in terms of milli
seconds.
 Energy can be obtained from
1. Explosive forming- Using chemical energy
in explosive material
2. Electric spark or Electro – hydraulic – using
electric energy
3. Electro Magneto – using electric energy
 High velocity forming process

 Energy can be given with the help of high

velocity
 Ram/ die can moved quickly.
 Since KE is proportional to velocity square.
 Small size ram is sufficient.
 Movement can be achieved by energy stored in
air/gas or petrol or diesel.
 Explosive Forming Cont…..
 Are classified in two methods
• 1. Confined Explosive forming
• 2. Unconfined Explosive forming

• A charge, detonated either above or within pressure

transmitting medium generates high pressure shock
waves, which can be used to form parts.
 Explosive forming Cont…..
 Confined System
 Explosive forming Cont…..
 Used for smaller and tubular parts for bulging
operation.
 Not mostly used process because,
 Damage of dies because of high pressure shock

wave generation and die erosion.

In this process vacuum should be provided in the
die and workpiece, otherwise problem of
adiabatic compression of trapped air.
Unconfined Explosive forming
 Unconfined Explosive forming Cont…..
 In this process shock waves are transmitted
through the water as a medium.
 Used for forming large size parts up to 25 mm
thickness.
 Used for fabricating ship building operation.
 Important point is
 Unconfined Explosive forming Cont…..
 Stand off Distance
 Workpiece to Explosive material
 Or
 Explosive material to Water level
 If Workpiece to Explosive material is small-
more energy transmittance
 If Explosive material to Water level is small –
less energy transmittance
 Unconfined Explosive forming Cont…..
 Explosive materials
 Dynamite
 amatol
 RDX- (Cyclotrimethylenetrinitramine)
 TNT-(tri-nitrotoluene)
 Tetryl
 Advantage of Water over Air
 Water less compressible so complete energy
transfer, where as air is compressible low
energy transfer.
 Under water, noise level is low.
 Possibility of damage to the die also low.

Injection Moulding
Injection molding- Screw
Extrusion Moulding
Compression moulding
Transfer Moulding
Calendaring Process