SHEET METAL

FORMING
Topic

SHEET METAL FORMING –

1. Blanking and piercing, Forces and power requirement in these
operations,
2. Deep drawing, Stretch forming,
3. Bending, Springback and its remedies,
4. Coining, Spinning,
5. Types of press and press tools.
PROCESSING OF PLASTICS:
Types of Plastics,
Properties, Applications and their processing
methods, Blow molding
Injection molding
BLANKING AND PIERCING:

The metal cutting is a process used for separating a piece of material of

predetermined shape and size from the remaining portion of a strip or
sheet of metal. It is one of the most extensively used processes
throughout die and sheet-metal work. It is consists of several different
material-parting operations, such a piercing, perforating and shearing,
notching, cut-off and blanking.

In blanking, the piece is cut off from the sheet and it becomes a finished
part. In piercing, the cut-out portion is scrap which gets disposed off while
the product part travels on through the remainder of the die. The
terminology is different here, though both processes are basically the
same and therefore belong to the same category, which is the process of
metal cutting figure given by

Blanking and piercing differentiation.

The actual task of cutting is subject to many concerns. The quality of

surface of the cut it condition of the remaining part, straightness of the
edge, amount of burr, dimensional stability all these are quite complex
areas of interest, well known to those involved in sheet metal work.

Most of these concerns are based upon the condition of the tooling and its
geometry, material thickness per metal cutting clearance, material
composition and amount of press force, accurate locating under proper
tooling and a host of additional minor criteria. These all may affect the
production of thousands and thousands of metal stamped parts.

6.1.1 Forces and power requirement in these operations, Deep drawing,

Bending, Springback and its remedies, Coining, Spinning,

BENDING

The bending is a metal forming process in which a force is applied to a

piece of sheet metal, causing it to bend at an angle and form the desired
shape. A bending operation causes deformation along one axis, but a
sequence of
several different operations can be performed to create a complex part.
Bent parts can be quite small, such as a bracket or up to 20 feet of length,
such as a large enclosure or chassis. A bend can be characterized by
several different parameters, shown in the figure below.

Bending Diagram

Bend line - The straight line on the surface of the sheet, on either side of
the bend, that defines the end of the level flange and the start of the
bend.

Outside mold line - A straight line where the outside surfaces of the two
flanges would meet, were they to continue. This line defines the edge of a
mold that would bound the bent sheet metal.

Flange length - The length of either of the two flanges, extending from
the edge of the sheet to the bend line.

Mold line distance - The distance from either end of the sheet to the
outside mold line.

Setback - The distance from either bend line to the outside mold line.
Also equal to the difference between the mold line distance and the flange
length.
Bend axis - The straight line that defines the center around which the
sheet metal is bent.

Bend length - The length of the bend, measured along the bend axis.

Bend radius - The distance from the bend axis to the inside surface of
the material, between the bend lines. Sometimes specified as the inside
bend radius. The outside bend radius is equal to the inside bend radius
plus the sheet thickness.

Bend angle - The angle of the bend, measured between the bent flange
and its original position or as the included angle between perpendicular
lines drawn from the bend lines.

Bevel angle - The complimentary angle to the bend angle

DEEP DRAWING:

Deep drawing is steel metal forming process in which a sheet metal

blank is radially drawn into a forming die by the mechanical action of a
punch. It is thus a shape transformation process with material retention.

Diagrammatic representation of Deep drawing test

Surface testing

A surface test is conducted to evaluate the amount of water that can be

pumped from a particular water well. More specifically, a well test will
allow prediction of the maximum rate at which water can be pumped from
a well and the distance that the water level in the well will fall for a given
pumping rate and duration of pumping
 Diagrammatic representation of Surface testing

Corrosion testing

A reversal of the prevailing trend is price movement for a security. The

term is most often used to describe a decline after a period of rising
prices. A correction is often considered beneficial for the long term
health of the market, in that the prices had risen too quickly and drop
them backto more realistic levels.

Diagrammatic representation of Corrosion testing

Pressing:

A machine press is a machine tool that uses pressure to cut or shape

pieces as part of a manufacturing process. Machine press use a variety of
means to apply pressure, including hydraulic, pneumatic and
mechanical, the particular type of machine press used may be dependent
on the material to be shaped or cut, as well as the specifications of the
end product.

Die:

Hollow or solid metal form used in cutting or stamping coins or shapes,

drawing bars or wires, embossing, extruding or threading inside or
outside.

Diagrammatic representation of Die

Basic Shearing Operations

The broad classification of sheet metal operations falls under the following
two categories.

1. Cutting operations.
2. Forming operations

1.Cutting operations

In cutting operations, the work piece is stressed beyond its ultimate

strength and cut-off into two pieces. In forming operations, the stresses
are below the ultimate strength of the metal. There is no cutting off metal
but only the contour of the work piece is changed to get the desired
product.

The common cutting operations are discussed below.

(a)Blanking:

Diagrammatic representation of Blanking and piercing or punching

Blanking is the operation of cutting a flat shape from the sheet metal. The
metal that is punched out is called as ‗blank‘ and the metal that is left out
is called as scrap.

(b) Punching or Piercing: It is the operation of producing the hole on the

work piece by a punch. In punching, the metal removed is called as a
scrap and the metal that is left out is called as work piece.

(c) Shearing: It is the operation through which a metal is cut along a

single line, usually a straight line.

(d) Parting: It is the operation through which the metal is cut

simultaneously along two parallel lines or contours or any other two lines
which can balance each other to neutralize side thrust.

Diagrammatic representation of Shearing

 Diagrammatic representation of Notching

(e) Notching: It is the operation through which metal pieces are cut from
the edges of sheet, strip or blank.

(f) Trimming: It is the operation used for removing excess metal, irregular
outlines and waved edges etc., from the walls of drawn shells or the
surfaces of waved and cast parts.

(g) Shaving: It is also similar to trimming operations but here the amount
of metal removal is usually about 10% of the thickness of the blank.

(h) Perforating: In this operation, multiple holes which are very small and
close together are cut in to flat work material.

(i) Slitting: It is the operation of making an unfinished cut through a

limited length .

(j) Lancing: Lancing consists of cutting the sheet metal through a small
length and bending this small cut portion downwards.

Diagrammatic representation of Slitting and perforating

 Diagrammatic representation of Lancing

2.Forming operations

(a) Bending: Bending is the operation of forming the metal between a

suitably shaped punch and a forming block. The included angle on the
tools is usually smaller than that to be produced to allow for the ‗spring
back‘ of the metal after forming. Spring back is a term which denotes the
property of sheet metal to partially fall back from its bent position when
the punch retards after completing the operations.

(b) Drawing: Drawing operations consists of a punch forcing a sheet metal

into the clearances available between the punch and die surface so as to
acquire a cylindrical shape or a box shape.

(c) Squeezing: In squeezing operation, the metal is caused to flow to all

portions of cavity under the action of compressive force.

Diagrammatic representation of Drawing

 Diagrammatic representation of Embossing

(d) Embossing: It is the process of producing required shapes on sheet

metal blanks of punches and dies.

(e) Nibbling: Nibbling is an operation of cutting any shape from sheet

metal without metal tools. It is done on a nibbling machine. The required
shape of it is connected in the form of tracer or templates in nibbling
machine. Time taken to cut the required shape is less when compared to
other processes.

3. Bending Operations

Bending is the operation of forming the metal between a suitable shaped

punch and a forming blank.

There are different types of bending operations as follows:

1. Angle bending
2. Roll bending.
3. Roll forming
4. Seaming.

Angle Bending

In this case metal is bent at an angle to each edge.

 Diagrammatic representation of Angle bending

Roll bending

Three-roll bending pushes an extrusion around three different rolls placed

in a triangular shape. The rolls are adjusted to form a precise angle, up to
a 360-degree rotation, that can roll horizontally or vertically.

As the extrusion is slowly moved across the power-driven rollers, it begins

to curve and bend.

Diagrammatic representation of Roll bending

Roll Forming

If the edges are formed to a desired shape or any impression in the form
of bend is made on the sheet metal, it is called as roll forming
operations.

Diagrammatic representation of Roll forming

Seaming

Seaming is a sheet metal joining process. Seaming involves bending the

edges of two parts over each other.As the bends are locked together,
each bend helps resist the deformation of the other bend, providing a well
joint structure.

Diagrammatic representation of Seaming

Sheet metal Involves a wide range of processes that manufacture parts

for a vast amount of purposes, both seen and unseen. Sheet metal refers
to metal that has a high surface area to volume ratio. Sheet metal
used for
sheet metal processes, is usually formed by rolling and comes in the
form of coils.

Common tools:

•Beginning the Cut with a Punch.

•Cutting with Hawk-Billed Snips.

•Grooving an Outside Seam.

•Turning the Flange.

•Hammer.

Diagrammatic representation of Tools

Each and every sheet metal processes are having different characteristics,

1. Roll forming
2. Stretch forming
3. Drawing.
4. Stamping.
5. Rubber forming
6. Spinning.

(1) Roll Forming

Long parts with constant complex cross sections, good surface finish, high
production rates and high tooling coasts are produced.

(2) Stretch Forming

Large parts with shallow contours suitable for low-quantity production,
high labour costs, tooling and equipment cost depending on part size are
produced.

In plug drawing, both internal and external surface of the tube is

controlled and the dimensional accuracy is good compared with other two
methods.

(3)Drawing

Shallow or deep parts with relatively simple shapes, high production

rates, high tooling and equipment‘s costs are produced.

(4)Stamping

It includes a variety of operation such as punching, blanking, embossing,

bending, flanging and coining simple (or) complex shapes formed at high
production rates, tooling and equipment costs can be high but labour cost
is low.

(5)Rubber Forming

It includes drawing and embossing of simple or complex shapes, sheet

surface protected by rubber membranes, flexibility of operation, low
tooling costs.

(6)Spinning

Small or large axisymmetric parts good surface finish, low tooling costs,
but labour costs can be high unless operations are automated

STRETCH FORMING:

There are two methods.

* From-block method.

* Making-die method.

1) From Block Method: In this method, the two ends of the blank or
sheet metal is tightly held by an adjustable gripper. These grippers are
fixed but adjustable. In this case, the form-block is operated by hydraulic
cylinder. The movement of the cylinder always depends on the hydraulic
fluid pressure. Force exerted on the piston is calculated as,

F = π/4 d2p.

d = Diameter of the piston.

P = Hydraulic fluid pressure.

 Diagrammatic representation of Block method

Stretching the blank can also be done by fixing the form block stationary
and moving the grippers . It is performed by holding the blank in movable
grippers.

2) Making Die Method: In this method block is held in movable grippers.

The lower die is kept stationary and upper die is movable which is
operated by hydraulic cylinder. next upper die is moved towards the
blank. Due to continuous stretching of the blank by the upper die plastic
flow of sheet metal takes place between lower and upper die. When the
upper die edge reaches the top surface of the blank, the stretching
process is completed.
 Diagrammatic representation of Respect to tension

Diagrammatic representation of Towards down

Material Die Blocks: Wood, Masonite, ZIC.

Advantage:

*Tolling cores are low.

*Direct bending is not introduced.

*Plastic deformation is due to pure tension only.

Disadvantage:

*Blank thickness should be uniform throughout the length.

*Sudden changes in contour surfaces can‘t be stretched.

*The process requires high quality from blocks.

SPINNING
The process of forming seamless metal parts from a circular sheet metal
or from a table length on a lathe is called as spinning process.

There are two methods used to produce sheet metal parts.

1. Manual spinning.

2. Power spinning.

Manual Spinning: The circular blank is centred on a lathe which is

placed against a form block, momented on the head stock of the spinning
lathe. The blank is tightly held between form block and tail stock spindle.
The required contour surface is made on the form block. The required
shape is gradually formed by continuous application of pressure by the
roller.

Diagrammatic representation of Manual pinning

Power Spinning Process: The quality of finished products mainly

depends on the skill and experience of the operator. Accuracy of the
finished products is also less in manual spinning process. Even though
segmental chucks are used for making complex shapes, the metal
thickness and contour shapes are restricted in manual spinning. In order
to ensure skill of the operator and reduced machining time, spinning
machines are referred as power spinning.
Diagrammatic representation of Power spinning process

COINING

Coining is the squeezing of metal while it is confined in a closed set of dies.

A workpiece is placed a confined die. A movable punch is located within

the die. The action of this punch cold works the material and can form
intricate features.

coining

This process is used to produce coins, medallions and other similar

products on flat stock with relief features. Very fine detail can be
reproduced. Pressures as high as 1375 MPa (200,000 psi) is required to
generate very fine features.

SPINNING:
The spinning is to process used for making cup shaped articles which are
axisymmetrical. Two process of spinning consisting of rotating two blank,
fixed against the form block and then applying a gradually moving force
on the blank takes the shape of the form block.

A during spinning the tools are moved relative to the rotating work piece
19 to 23. Spinning belongs to the tension and compression forming
processes since tangential compressive and radial tensile stresses are
generated in the deformation zone just as in deep drawing. It has become
necessary to study the process variable and their effect on the product to
eliminate costly errors in the trial and error method. The increase in
civilian and military items produced by power spinning also explain why
more attention has latterly been directed to the study of this process. The
spinning process as shown in figure

Spinning operation

TYPES OF PRESS AND PRESS TOOLS:

Classification of press.

Types of press for sheet metal working can be classified by one or a

combination of characteristics, such as source of power, number of slides,
type of frame and construction, type of drive and intended applications.

Typical press
Classification on the basis of source of

power. Manual Press.

These are either hand or foot operated through levers, screws or gears. A
common press of this type is the arbor press used for assembly
operations.

Mechanical press.

The press utilize flywheel energy which is transferred to the work piece
by gears, cranks, eccentrics or levers.

Hydraulic Press.

These press provide working force through the application of fluid

pressure on a piston by means of pumps, valves, intensifiers and
accumulators. These press have better performance and reliability than
mechanical press.

Pneumatic Press.

These press utilize air cylinders to exert the required force. These are
generally smaller in size and capacity than hydraulic or mechanical press
and therefore find use for light duty operations only.

Classification on the basis of number of

slides. Single Action Press.

A single action press has one reciprocation slide that carries the tool for
the metal forming operation. The press has a fixed bed. It is the most
widely used press for operations like blanking, coining, embossing and
drawing.

Double Action Press.

A double action press has two slides moving in the same direction against
a fixed bed. It is more suitable for drawing operations, especially deep
drawing, than single action press. For this reason, its two slides are
generally referred to as outer blank holder slide and the inner draw slide.

The blank holder slide is a hollow rectangle, while the inner slide is a solid
rectangle that reciprocates within the blank holder. The blank holder slide
has a shorter stroke and dwells at the bottom end of its stroke, before the
punch mounted on the inner slide touches the workpiece. In this way,
practically the complete capacity of the press is available for drawing
operation.

Another advantage of double action press is that the four corners of the
blank holder are individually adjustable. This permits the application of
non uniform forces on the work if needed.
A double action press is widely used for deep drawing operations and
irregular shaped stampings.

Triple Action Press.

A triple action press has three moving slides. Two slides (the blank holder
and the inner slide) move in the same direction as in a double action press
and the third or lower slide moves upward through the fixed bed in a
direction opposite to that of the other two slides. This action allows
reverse drawing, forming or bending operations against the inner slide
while both upper actions are dwelling.

Cycle time for a triple action press is longer than for a double action press
because of the time required for the third action.

PRESS TOOL:

A press tool are commonly used in hydraulic, pneumatic and mechanical

press to produce components at high volumes. Generally press tools are
categorized by the types of operation performed using the tool, such as
blanking,piercing, bending, forming, forging, trimming etc. The press tool
will also be specified as a blanking tool, piercing tool, bending tool etc..

Classification of press tools:

Blanking Tool:

• When a component is produced with one single punch and die where the
entire outer profile is cut in a single stroke the tool is called a blanking
tool.

• Blanking is the operation of cutting flat shapes from sheet metal.

• The outer area of metal remaining after a blanking operation is

generally discarded as waste.

• The size of blank or product is the size of the die & clearance is given on
punch.

• One of the metal cutting operation.

Piercing tool:

A piercing involves cutting of clean holes with a resulting scrap slug. The
operation is called die cutting and can also produce flat components
where the die, the shaped tool, is pressed into a sheet material employing
a shearing action to cut holes. This method can be used to cut parts of
different sizes and shapes in sheet metal, leather and many other
materials.

Cutoff tool:

The cut off operations are those in which a strip of suitable width is cut to
length in a single operation. Cut-off tools can produce many parts. The
required length of strip can be cut off for bending and forming operations
using this tool
Parting off tool

Partings are similar, in that a discrete part is cut from a sheet or strip of
metal along a desired geometric path. The difference between a cutoff
and a parting is that a cutoff can be nestled perfectly on the sheet metal,
due to its geometry. With cutoffs, the cutting of sheet metal can be done
over one path at a time and there is practically no waste of material. With
partings, the shape can not be nestled precisely. Partings involve cutting
the sheet metal along two paths simultaneously. Partings waste a certain
amount of material, that can be significant.

Trimming tool

When cups and shells are drawn from flat sheet metal the edge is left
wavy and irregular, due to uneven flow of metal. This irregular edge is
trimmed in a trimming die. Shown is flanged shell, as well as the trimmed
ring removed from around the edge. While a small amount of Material is
removed from the side of a component in trimming tool.
Shaving tool

The shaving removes a small amount of material around the edges of a

previously blanked stampings or piercing. A straight, smooth edge is
provided and therefore shaving is frequently performed on instrument
parts, watch and clock parts and the like. Shaving is accomplished in
shaving tools especially designed for the Purpose.

Bending tool

Bending tools apply simple bends to stampings. A simple bend is done in

which the line of the bend is straight. One or more bends may be involved
and bending tools are a large important class of press tools.

Forming tool

Forming tools apply more complex forms to work pieces. The line of bend
is curved instead of straight and the metal is subjected to plastic flow or
deformation.

Drawing tool

The drawing tools transform flat sheets of metal into cups, shells or other
drawn shapes by subjecting the material to severe plastic deformation.
Shown in fig is a rather deep shell that has been drawn from a flat sheet.
This type of Press tool is used to perform only one particular
operation therefore classified under stage tools.

Progressive tool

A progressive tool differs from a stage tool in the following respect: in a

progressive tool the final component is obtained by progressing the sheet
metal or strip in more than one stage. At each stage the tool will
progressively shape the component towards its final shape, with the final
stage normally being cutting-off.

Progressive tool

Compound tool

The compound tool differs from progressive and stage tools by the
arrangement of the punch and die. It is an inverted tool where blanking
and
piercing takes place in a single stage and also the blanking punch will act
as the piercing die.

Compound tool

Combination tool

In a combination tool two or many operations such as bending and

trimming will be performed simultaneously. Two or many operations such
as forming, drawing, extruding, embossing may be combined on the
component with various cutting operations like blanking, piercing,
broaching and cut off takes place it can perform a cutting and non cutting
operations in a single tool.

Combination tool