Macam Proses

Operasional
Mekanisme
Benda Kerja
pemotongan Cutting Bending and
Drawing Forming
(Shearing) Yg dihasilkan
( Shearing)

Sheet Metal
Forming Processes

Keunggulan Gaya yg
Proses Parameter dibutuhkan
Proses
Sheet-Metal Forming Processes Chapter 16
 Mekanisme Macam Proses Operasional Produk Yg
pemotongan dihasilkan
Shearing Blanking, Piercing, Notching, Shaving, Blanking Part, Piercing
Gaya tekan, Punch, Semi-notching, Perforating, Slitting, Nibling, Part, Notching Part,
Die, celah, bidang Semi Notching Part,
geser, deformasi Shaving Part,
elastis, plastis, Preforating Part,
fracture.

Shearing

Keunggulan Gaya Potong

Proses (Cutting Force /
Hemat bhn baku,
Parameter Proses Shear Force)
sifat mekanik Gaya, celah, radius
meningkat Die, radius punch, F = A. (Ƭs)
lubricant, gesekan,
rasio Do/Dp, gaya F = 0.7 T L (σt )
blank holder.
 Meknisme Macam Proses Operasional Produk Yg
pembentukan dihasilkan
Bending, Hemming, Roll Forming, Deep
Drawing , Bead Forming, Flanging Lemari cabinet,
Deformasi elastis, Operation, Embossing mangkok, tempat filter
Deformasi plastis oli, White Board Marker,
Spring back Collar Drawing,

Bending and Drawing Gaya Bending

kYLT 2
P
W
where
Keunggulan k = 0.3 for wiping die,
Proses Parameter Proses k = 0.7 for a U - die,
Hemat bhn baku, Gaya, celah, radius k = 1.3 for a V- die
sifat mekanik Die, radius punch, Gaya Deep Drawing,
meningkat lubricant, gesekan,
rasio Do/Dp, gaya blank  D  
Fmax  DpT UTS o  0.7
holder. 
Dp  

 Macam Proses Operasional Produk Yg
Mekanisme Stretch Forming, Spinning, Hidro Forming, dihasilkan
Rubber Forming, Magnetie-Pulse Forming,
pembentukan Knalpot, bentukan-
explosion forming, Superelastic forming. ,
bentukan dari bahan
stretch forming, peen, stamping
pipa, Mangkok dng
Deformasi elastis, lekukan, berbagai
Deformasi plastis bentuk mangkok

Forming

Keunggulan
Proses
Hemat bhn baku,
Parameter Proses Gaya
sifat mekanik Gaya, jenis bahan, pembentukan
ketebalan, Tekanan,
meningkat
pelumasan
Tergantung
proses
Mesin Press

Alat bantu
Cetakan

Matres

Punch n Die

Cutting

Forming
Die
Punch
and Die

Matres
Kelengkapan proses sheet metal forming
 14 steps

Lay out strip

Automatic Stop
Back Gage

Die block Finger stop

Urutan proses Stripper

Pilot
Blanking perencanaan Die
Punch

Fastener

Piercing Punch plate

Punch

Langkah langkah pembuatan die

 Characteristics of Sheet-Metal Forming Processes

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Mekanisme pemotongan (shearing) logam lembaran

Elastis

Plastis

Fracture
Berapa kebutuhan
Gaya potong
(Punch Force )

F = 0.7 T L (UTS)

F = 0.7 A (UTS)

F = A. Ʈs

Tegangan Geser
 Shearing

Figure 16.3 (a) Effect of the clearance, c, between punch and die on
the deformation zone in shearing. As the clearance increases, the
material tends to be pulled into the die rather than be sheared. In
practice, clearances usually range between 2 and 10% of the thickness
of the sheet. (b) Microhardness (HV) contours for a 6.4-mm (0.25-in.)
thickManufacturing,
AISI 1020 hot-rolled steel in the sheared region.
Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Source: After H.P Weaver and K.J.
Weinmann.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Die-Cutting Operations
• Piercing
Blanking, Piercing , …….. • Notching
• Lanzing
• Perforating
• Semi notching
• Shaving
• Trimming
• Slitting
• Nibbling
• Parting
• Lancing

Figure 16.4 a). Punching (piercing) and blanking. (b) Examples

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
of various die-cutting
ISBN 0-13-148965-8. operations
© 2006 Pearson onSaddle
Education, Inc., Upper sheet River, metal.
NJ. All rights reserved.
 Shearing - Main Processes
o Punching: to create holes (sheared slug is discarded)
o Blanking: to cut various shapes from sheet stock (the slug
is the part, the rest is scrap)
o Perforating: punching a number of holes in a sheet
o Parting: shearing a sheet into two pieces
o Notching: removing pieces or various shapes from edges
o Nibbling: in nibbling a machine called a nibbler moves a
straight punch up and down rapidly into a die
o Lancing: is a useful combination of cutting and shallow
forming all in one operation (e.g. cooling louvers)
o Fine Blanking: an impingement ring locks the part tightly
in place to prevent edge distortion (burr free parts are
produced)
 Conventional Versus Fine-Blanking

Figure 16.5 (a) Comparison of sheared edges produced by conventional

(left) and by fine-blanking (right) techniques. (b) Schematic illustration of
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
one setup for fine
ISBN 0-13-148965-8. blanking.
© 2006 Pearson Education, Inc., Upper Saddle
Source: River, NJ.
Courtesy of All rights reserved.
Feintool U.S. Operations.
 Slitting with Rotary Knives

Figure 16.6 Slitting with rotary knives. This process is

similar to opening cans.
 Tailor-Welded Blanks

FigureManufacturing,
16.7 Production of anFifthouter
Engineering & Technology, Edition, byside panelandofSteven
Serope Kalpakjian a car body by laser butt-welding
R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Examples of Automotive Components
Produced from Tailor-Welded Blanks

FigureManufacturing,
16.8 Examples of laser
Engineering & Technology, butt-welded
Fifth Edition, and
by Serope Kalpakjian and stamped
Steven R. Schmid.automotive-body
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 The Shaving Process

Figure 16.9 Schematic illustrations of the shaving process.

(a) Shaving a sheared edge. (b) Shearing and shaving
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
combined in one
ISBN 0-13-148965-8. stroke.
© 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Shear Angles

Upaya2 modifikasi untuk mengurangi gaya potong

Gb 10. Contoh2 penggunaan sudut geser pada Punch dan

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Die. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Compound
Die and
Progressive
Die

Figure 16.11 Schematic illustrations: (a) before and (b) after blanking a common
washer in a compound die. Note the separate movements of the die (for blanking)
and the punch (for punching the hole in the washer). (c) Schematic illustration of
making a washer in a progressive die. (d) Forming of the top piece of an aerosol
spray can in a Engineering
Manufacturing, progressive die.
& Technology, Note
Fifth Edition, thatKalpakjian
by Serope the part is attached
and Steven R. Schmid. to the strip until the
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
last operation is completed.
 Transfer dies :
• Logam lembaran mengalami operasi yang berbeda pada stasiun
yang berbeda dalam garis lurus atau jalur melingkar

Tool and Die Material :

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Characteristics of Metals Used in Sheet-Forming

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
• Baja karbon rendah menunjukkan perilaku ini :
Sheet Metal
• Ini menghasilkan Lüder’s band (stretch strain marks)
• Tanda ini dpt dieliminasi dgn pengurangan ketebalan dari 0.5 % sampai
1.5 % dng proses roll dingin.

Figure 16.12 (a) Yield-point elongation in a sheet-metal

specimen. (b) Luder’s bands in a low-carbon steel sheet. (c)
Stretcher strains at the bottom of a steel can for household
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
products. Source:
ISBN 0-13-148965-8. © 2006 (b) Courtesy
Pearson Education, Inc.,ofUpper
Caterpillar IncAll. rights reserved.
Saddle River, NJ.
 Cupping Test and Bulge-Test
Spesimen logam lembaran dijepit dng gaya blank holder ditekan dng
penggerak hidrolik sampai retak mulai muncul pada spesimen

Figure 16.13
(a) A cupping test (the Erichsen test) untuk menentukan kemampuan bentuk.
(b) Hasil uji dng variasi lebar plat. Sampel paling kiri sdl terkena tarikan. Sampel paling kanan
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
mengalami biaxial
ISBN 0-13-148965-8. stretching.
© 2006 Source:
Pearson Education, Inc., UpperCourtesy of AllInland
Saddle River, NJ. Steel Company.
rights reserved.
 Diagram Batas Pembentukan
(Forming Limit Diagram)

Figure 16.14 (a)

Strains in deformed
circular grid patterns.
(b) Forming-limit
diagrams (FLD) for
various sheet metals.
Although the major
strain is always positive
(stretching), the minor
strain may be either
positive or negative. In
the lower left of the
diagram, R is the normal
anisotropy of the sheet,
as described in Section
16.4. Source: After S .S
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Hecker and A. K. Ghosh.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Deformation and Tearing in Sheet Metal During Forming

Figure 16.15 The deformation of the grid pattern and the tearing of sheet
metal during forming. The major and minor axes of the circles are used
to determine the coordinates on the forming-limit diagram in Fig. 16.14b.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Source:ISBN
After S. P. Keeler
0-13-148965-8. . Education, Inc., Upper Saddle River, NJ. All rights reserved.
© 2006 Pearson
 Bending Terminology

Figure 16.16 Bending terminology. Note that the bend radius

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
is measured
ISBN 0-13-148965-8.to the
© 2006 inner
Pearson surface
Education, Inc., ofNJ.the
Upper Saddle River, All rightsbent
reserved. part.
 Effect of Elongated Inclusions
• In bending outer fibers are in tension and inner fibers are in compression

Figure 16.17 (a) and (b) The effect of elongated inclusions stringers) on
cracking as a function of the direction of bending with respect to the
original rolling direction of the sheet. (c) Cracks on the outer surface of
an aluminum strip bent to an angle of 90 degrees. Note also the
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
narrowing of the©top
ISBN 0-13-148965-8. surface
2006 Pearson Education,in Inc.,the bend
Upper Saddle River,area (due
NJ. All rights to Poisson effect).
reserved.
 Minimum Bend Radius

Figure 16.18 Relationship between R/T ratio and tensile reduction of area for
sheet metals. Note that sheet metal with 50% tensile reduction of area can be
bent over itself in a process like the folding of a piece of paper without cracking.
Source: After J. Datsko and C. T. Yang.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Springback in Bending
Springback adalah
pemulihan secara elastis
ketika beban bending
dilepaskan. Dapat dihitung
dengan rumus sbb.:

Ri RiY 3 RiY  Dimana Ri dan Rf adalah radius bending awal dan
 4   3 1 akhir, sedangkan Y adalah tegangan luluh material
Rf ET  ET 
dan E modulus elastis

Figure 16.19 Springback in bending. The part tends to recover elastically

after bending, and its bend radius becomes larger. Under certain
conditions, it is possible for the final bend angle to be smaller than the
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
original
ISBNangle (negative
0-13-148965-8. © 2006 Pearson springback).
Education, Inc., Upper Saddle River, NJ. All rights reserved.
Hubungan antara sudut dan radius bending:
T
Arc length unchanged T/2

a
i
Ri R
f
After

a f

Before af

af (Rf + T/2) = ai (Ri + T/2)

 Methods of Reducing or Eliminating Springback

FigureManufacturing,
16.20 Methods of reducing or eliminating springback in bending
Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
operations. Source:
ISBN 0-13-148965-8. After
© 2006 V.Education,
Pearson Cupka, Inc.,T. Nakagawa,
Upper and
Saddle River, NJ. H. Tyamoto
All rights reserved. .
 Common Die-Bending Operations
Bending Force

kYLT 2
P
W
where
Figure 16.21 Common die-bending k = 0.3 for wiping die,
operations showing the die-opening
dimension, W, used in calculating bending k = 0.7 for a U - die,
forces.
k = 1.3 for a V- die
For a V-die
Max bending force, P = (UTS)LT2 Y - yield stress
L - length of the bend
W T - thickness of sheet
UTS – Ultimate tensile strength

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Bending Operations

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Figure 16.22 Examples of various bending operations.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Press Brake

Figure 16.23 (a) through (e) Schematic illustrations of various

bending operations in a press brake. (f) Schematic illustration of
a press
ISBN brake.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
0-13-148965-8. © Source: Courtesy
2006 Pearson Education, of Verson
Inc., Upper Allsteel
Saddle River, Company.
NJ. All rights reserved.
 Bead Forming

Figure 16.24 (a) Bead forming with a single die. (b) and (c)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Bead ISBN
forming
0-13-148965-8. ©with two
2006 Pearson dies
Education, inSaddle
Inc., Upper a River,
press brake
NJ. All rights reserved. .
 Flanging Operations
o Flanging is a process of bending the edges of sheet metals to 90 o
o Shrink flanging – subjected to compressive hoop stress.
o Stretch flanging –subjected to tensile stresses

Figure 16.25 Various

flanging operations.
(a) Flanges on a flat
sheet. (b) Dimpling.
(c) The piercing of
sheet metal to form a
flange. In this
operation, a hole
does not have to be
pre-punched before
the punch descends.
Note, however, the
rough edges along
the circumference of
the flange. (d) The
flanging of a tube.
Note the thinning of
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
the edges of the
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. flange.
 Roll-Forming Process
 Roll forming is used for continuous lengths of sheet metal
 Used for large production runs

Figure 16.26 (a) Schematic illustration of the roll-forming process. (b)

Examples of roll-formed cross-sections. Source: (b) Courtesy of Sharon Custom
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Methods of Bending Tubes
• Special tooling required to avoid buckling and folding

Figure 16.27 Methods of bending tubes. Internal mandrels or filling of

tubes with particulate materials such as sand are often necessary to
prevent collapse of the tubes during bending. Tubes also can be bent by
a technique consisting if a stiff, helical tension spring slipped over the
tube. Manufacturing,
The clearance between the OD of the tube and the ID of the spring
Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
is small,
ISBN thus the© 2006
0-13-148965-8. tube cannot
Pearson kick
Education, Inc., Upper and theNJ.bend
Saddle River, is uniform.
All rights reserved.
Bulging : Proses melibatkan menempatkan bagian tabular, kerucut
atau lengkung ke dalam Female Die dan diekspansi

Tubular Parts

Figure 16.28 (a) The bulging of a tubular part with a flexible plug. Water
pitchers can be made by this method. (b) Production of fittings for plumbing by
expanding tubular blanks under internal pressure. The bottom of the piece is then punched out
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
to produce
ISBNa “T.” Source
0-13-148965-8. : After
© 2006 J. A.
Pearson Schey.Inc., Upper Saddle River, NJ. All rights reserved.
Education,
 Manufacturing of Bellows

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Figure 16.29 Steps in manufacturing a bellows.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Stretch-Forming Process

Gb 30.Manufacturing,
IlustasiEngineering
proses stretch-forming. Aluminum skins for aircraft can be
& Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
made by
ISBNthis method.
0-13-148965-8. Source:
© 2006 Pearson Education,Courtesy of Cyril
Inc., Upper Saddle Bath
River, NJ. Co.
All rights reserved.
 - ME350 -
Deep
Drawing
- ME350 -
 Can
Manufacture

Figure 16.31
The metal-
forming
processes
involved in
manufacturing
a two-piece
aluminum
beverage can.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 D  
Deep-Drawing Fmax  DpT UTS o  0.7

Dp  




Figure 16.32 (a) Schematic illustration of the deep-drawing process on a

circular sheet-metal blank. The stripper ring facilitates the removal of the
formed cup from the punch. (b) Process variables in deep drawing.
Except for the punch force, F, all the parameters indicated on the figure
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
are independent
ISBN 0-13-148965-8. ©variables.
2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Technical Difficulties
Extrusion of battery can
requires ten stages of die
process and each stage
can not tolerate any
defect.

Too small Material holding Too large

pressure
Too large Die clearance
Too small
Punch R Too small
Wrinkles on flange Too large
drawing Breakage on punch
Die center radius
misalignment
Typical example of NG
Breakage on side wall extrusion parts
 - ME350 -

• Sifat Plate logam Radius Punch

• Rasio Do/Dp 4 s/d 6 kali dari ketebalan bahan
Terlalu kecil mengakibatkan sobek (tearing)
• Celah (clearance) Terlalu besar mengakibatkan kerutan
• Radius Punch (wrinkling)
• Gaya Blank holder Draw Ring Radius
• Gesekan 4 s/d 8 kali ketebalan bahan
Terlalu kecil menyebabkan fracture
• Pelumasan
Terlalu besar kecenderungan terjadi kerutan
(wrinkle) meningkat
 Penerapan Praktis proses Deep Drawing:

Tekanan pd Blank holder : 0.7% -1.0 % ( Teg luluh + UTS )

Celah : 7% -14 % lebih besar drpd ketebalan
Draw beads dpt digunakan untuk pengendali aliran
blank ke dalam cavity.
Ironing adl proses dimana ketebalan dinding mangkok
dibuat konstan dgn mendorong melalui ring.
Redrawing – Jika sulit untuk dilakukan drawing satu
operasi maka dilakukan drawing bertahap.
 - ME350 -
Pengaruh Parameter Pembentukan Yang Berbeda

Limit of wrinkling Limit of fracture

Drawability Window
 Normal and Average Anisotropy

Width strain 
Normal anisotropy, R   w
Thickness strain  t
R0  2R45  R90
Average anisotropy, Ravg 
4
Figure 16.33 Strains on a
tensile-test specimen
 of
removed form a piece
sheet metal. These strains
are used in determining the
normal and planar
anisotropy of the sheet
metal.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Relationship between Average Normal Anisotropy and
the Limiting Drawing Ratio

Maximum blank diameter Do

LDR  
Punch diameter Dp
FigureManufacturing,
16.34 Engineering
The relationship between average normal anisotropy and
& Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
the limiting drawing
ISBN 0-13-148965-8. ratioEducation,
© 2006 Pearson for various sheet
Inc., Upper Saddle River, NJ. metals. Source: After M. Atkinson.
All rights reserved.
 Earing and Planar Anisotropy

Edges of cups may be wavy this phenomenon is

called Earing
The above condition is called planar anisotropy
Del R = R0 – 2 R45 + R 90 / 2
Where Del R = 0 => no ears formed
Height of the ears increases Del R
increases.

R0  2 R45  R90
Planar anisotropy , R 
2
Note: If R=0, no ears form. The height of ears increases as 
R increases.
FigureManufacturing,
16.35 Engineering
Earing in a drawn steel cup caused by the planar anisotropy
& Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
of the ISBN
sheet metal.
0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Drawbeads

Figure 16.36 (a) Schematic illustration of a draw bead. (b) Metal flow
during the drawing of a box-shaped part while using beads to control the
movement of the material. (c) Deformation of circular grids in the flange
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
in deep drawing.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Embossing with Two Dies

Figure 16.37 An embossing operation with two dies. Letters,

numbers, and designs on sheet-metal parts can be produced by
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
this process.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Aluminum Beverage Cans

(a)

Figure 16.38 (a) Aluminum beverage cans. Note the excellent surface
finish.Manufacturing,
(b) Detail of the can lid showing integral rivet and scored edges
Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
for theISBN
pop-top.
0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Bending and Embossing of Sheet Metal

Figure 16.39 Examples of the bending and embossing of sheet metal with
a metal punch
Manufacturing, and &with
Engineering a flexible
Technology, padKalpakjian
Fifth Edition, by Serope serving asR. the
and Steven Schmid.female die. Source:
Courtesy of0-13-148965-8.
ISBN Polyurethane Products
© 2006 Pearson Corporation.
Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Hydroform Process

Figure 16.40 The hydroform (or fluid-forming) process. Note that in

contrast to the ordinary deep-drawing process, the pressure in the dome
forcesManufacturing,
the cup walls against the punch. The cup travels with the punch;
Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
in this ISBN
way, deep©drawability
0-13-148965-8. 2006 Pearson Education,is Inc.,improved.
Upper Saddle River, NJ. All rights reserved.
 Tube-
Hydroforming

Figure 16.41 (a) Schematic

illustration of the tube-
hydrofroming process. (b)
Example of tube-hydroformed
parts. Automotive exhaust and
structural components, bicycle
frames, and hydraulic and
pneumatic fittings are produced
through tube hydroforming.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
(b)
Source:ISBN of Schuler GmBH.
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Courtesy
 Conventional Spinning

Figure 16.42 (a) Schematic illustration of the conventional spinning

process. (b) Types of parts conventionally spun. All parts are
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
axisymmetric.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Shear-Spinning and Tube-Spinning

Figure 16.43 (a) Schematic illustration of the shear-spinning process for

making conical parts. The mandrel can be shaped so that curvilinear
parts can be spun. (b) and (c) Schematic illustrations of the tube-
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
spinning process© 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
ISBN 0-13-148965-8.
 Structures Made by Diffusion Bonding and Superplastic
Forming of Sheet Metals

Figure 16.44 Types of structures made by diffusion bonding and

superplastic forming of sheet metals. Such structures have a high
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
stiffness-to-weight
ISBN 0-13-148965-8. © 2006ratio. Source:
Pearson Education, Courtesy
Inc., Upper ofNJ.Rockwell
Saddle River, International Corp.
All rights reserved.
 Explosive Forming
• Explosive energy used a metal forming
• Sheet-metal blank is clamped over a die
• Assembly is immersed in a tank with water
• Rapid conversion of explosive charge into gas generates a shock wave
.the pressure of this wave is sufficient to form sheet metals

FigureManufacturing,
16.45 Engineering
(a) Schematic illustration of the explosive forming process.
& Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
(b) Illustration of© 2006
ISBN 0-13-148965-8. thePearson
confined
Education, Inc.,method of NJ.
Upper Saddle River, the explosive
All rights reserved. bulging of tubes.
 Magnetic-Pulse Forming Process

Figure 16.46 (a) Schematic illustration of the magnetic-pulse forming

process used to form a tube over a plug. (b) Aluminum tube collapsed
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
over a ISBN
hexagonal plug
0-13-148965-8. © 2006 byEducation,
Pearson the Inc.,magnetic-pulse forming
Upper Saddle River, NJ. All rights reserved. process.
 Cymbal
Manufacture

(a)

Figure 16.47 (a) A selection of common

cymbals. (b) Detailed view of different
surface textures and finishes of cymbals. (b)
Source: Courtesy of W. Blanchard,
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
SabianISBN
Ltd.
0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Cymbal Manufacture
(cont.)

Figure 16.48 Manufacturing

sequence for the production of
cymbals. Source: Courtesy of W.
Blanchard, Sabian Ltd.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Hammering of Cymbals

(a) (b)

Figure 16.49 Hammering of cymbals. (a) Automated hammering on a

peening machine;
Manufacturing, Engineering(b) hand
& Technology, Fifth hammering ofand
Edition, by Serope Kalpakjian cymbals.
Steven R. Schmid. Source: Courtesy of W.
Blanchard, Sabian Ltd.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Manufacturing Honeycomb Structures

Gb.50. Metode2 pembuatan struktur sarang lebah (a) expansion process;

(b) corrugation process; (c) assembling a honeycomb structure into a
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
laminate.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Efficient Part Nesting for Optimum Material Utilization

FigureManufacturing,
16.51 Engineering
Efficient nesting of parts for optimum material utilization in
& Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
blanking.
ISBN 0-13-148965-8. © 2006 Pearson
Source: Courtesy Education,
of Society of Inc., Upper Saddle River,
Manufacturing NJ. All .rights reserved.
Engineers
 Pengendali cacat pada Flange

Gb.52. Pengendali tearing dan buckling pada flange pada

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
tekukan sudut© 2006
ISBN 0-13-148965-8. kanan Source:
Pearson Education, Courtesy
Inc., Upper Saddle River,of
NJ.Society of Manufacturing Engineers.
All rights reserved.
 Penerapan Notches

Gb 53. penerapan notches untuk menghindari sobek dan

kerutan pada
Manufacturing, operasi
Engineering bending.
& Technology, Fifth Source:
Edition, by Serope Kalpakjian and Steven Courtesy
R. Schmid. of Society of
Manufacturing Engineers.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Konsentrasi tegangan dekat bending

Gb. Konsentrasi tegangan dekat area (a) penggunaan sebuah crescent

atau ear untuk
Manufacturing, lubang
Engineering dekat
& Technology, area
Fifth Edition, tekukan.
by Serope Kalpakjian and Source: Courtesy of Society of
Steven R. Schmid.
Manufacturing Engineers.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Memperoleh radius yg tajam dlm Bending.

Penerapan pada scoring or embossing untuk mendapatkan radius dlm

dlm bending. Jika tidak tepat dlm perancangan mk akan membawa
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
kondisi patah.
ISBN 0-13-148965-8. © 2006Courtesy
Source: Pearson Education,
of Society Inc.,
ofUpper Saddle River,Engineers.
Manufacturing NJ. All rights reserved.
 Kerangka mesin Press

Gb 56. a-f, ilustrasi jenis kerangka (frame). Masing2 mempunyai

karakteristik, kekakuan, kapasitas dan accessibility yg berbeda
 Perbandingan biaya proses spinning dibanding proses deep drawing.

Gb. 57. perbandingan biaya pembuatan rantang dengan proses spinning

dan deep drawing.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.