SHEET METALWORKING

1. Cutting Operations

2. Bending Operations

3. Drawing

4. Other Sheet Metal Forming Operations

5. Dies and Presses for Sheet Metal Processes

6. Sheet Metal Operations Not Performed on Presses

 Sheet Metalworking Defined

Cutting and forming operations performed on relatively thin sheets

of metal
 Thickness of sheet metal = 0.4 mm (1/64 in) to 6 mm (1/4 in)
 Thickness of plate stock > 6 mm
 Operations usually performed as cold working
High strength, good dimensional accuracy and surface finish,
relatively low cost and economical for mass production
Sheet metal products are used in-
Automobiles and trucks, Airplanes, Railway cars and locomotives
Farm and construction equipment, Small and large appliances
Office furniture, Computers and office equipment
 Basic Types of Sheet Metal
Processes
 Punch‑and‑die - tooling to perform cutting, bending, and drawing
 Stamping press - machine tool that performs most sheet metal
operations
 Stampings - sheet metal products

1. Cutting
 Shearing to separate large sheets
 Blanking to cut part perimeters out of sheet metal
 Punching to make holes in sheet metal
2. Bending
 Straining sheet around a straight axis
3. Drawing
 Forming of sheet into convex or concave shapes
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 Sheet Metal Cutting

 (1) Just before punch contacts work; (2) punch pushes into work, causing
plastic deformation; (3) punch penetrates into work causing a smooth cut
surface; and (4) fracture is initiated at opposing cutting edges to separate
the sheet

 Three principal operations in press working that cut sheet metal:

 Shearing
 Blanking
 Punching
 Shearing Operation

 (a) Side view of the operation; (b) front view of power

shears equipped with inclined upper cutting blade
 Blanking and Punching

 Blanking (a) - sheet metal cutting to separate piece

(called a blank) from surrounding stock
 Punching (b) - similar to blanking except cut piece is
scrap, called a slug
Fine blanking is a shearing operation used to blank
sheet-metal parts with close tolerances and smooth,
straight edges in one step, as illustrated in Figure. At the
start of the cycle, a pressure pad with a V-shaped
projection applies a holding force Fh against the work
adjacent to the punch in order to compress the metal and
prevent distortion. The punch then descends with a
slower-than-normal velocity and smaller clearances to
provide the desired dimensions and cut edges. The
process is usually reserved for relatively small stock
thicknesses.
 Clearance in Sheet Metal Cutting

Distance between punch cutting edge and die cutting edge

 Typical values range between 4% and 8% of stock thickness

 If too small, fracture lines pass each other
 If too large, metal is pinched between cutting edges and
excessive burr results

 Recommended clearance is calculated by:

c = at

where c = clearance; a = allowance; and t = stock thickness

 Allowance a is determined according to type of metal
Typical values: 0.25 to 1.5
on each side
 Other Sheet Metal Cutting
Operations
Slotting is the term sometimes used
for a punching operation that cuts out
an elongated or rectangular hole, as
pictured in Figure

Perforating involves the simultaneous

punching of a pattern of holes in sheet
Cutoff is a shearing operation in which metal, as in Figure
blanks are separated from a sheet-metal
To obtain the desired
strip by cutting the opposite sides of the
outline of a blank, portions
part in sequence, as shown in Figure. With
of the sheet metal are often
each cut, a new part is produced. The
removed by notching and
features of a cutoff operation that
seminotching. Notching
distinguish it from a conventional shearing
involves cutting out a
operation are (1) the cut edges are not
portion of metal from the
necessarily straight, and (2) the blanks can
side of the sheet or strip.
be nested on the strip in such a way that
Seminotching removes a
scrap
portion of metal from the
is avoided.
interior of the sheet.
 Sheet Metal Bending

 (a) Straining of sheet metal around a straight axis to take a

permanent bend
 (b) Metal on inside of neutral plane is compressed, while metal
on outside of neutral plane is stretched

 V‑bending –

performed with a V‑shaped die

 Edge bending –

performed with a wiping die

 V-Bending and Edge Bending

 (1) Before bending

 (2) After bending
 Application notes:
 Low production
 Performed on a press brake
 V-dies are simple and
inexpensive
Before Bending After Bending
 (1) Before bending
 (2) After bending
 Application notes:
 High production
 Pressure pad required
 Dies are more complicated
and costly
SPRINGBACK-Increase in included angle of bent part relative to included angle of
forming tool after tool is removed

 Reason for springback: When bending pressure is removed, elastic energy remains
in bent part, causing it to recover partially toward its original shape
Before Bending After Bending
 Other Sheet Metal Bending
Operations

Channel U Air
Bending Bending Bending

Offset Corrugating Tube

Bending Forming
 Sheet-Metal Drawing
(Deep Drawing of Cup)
Sheet metal forming to make cup‑shaped, box‑shaped, or other
complex‑curved, hollow‑shaped parts
 Sheet metal blank is positioned over die cavity and then punch
pushes metal into opening
 Products: beverage cans, ammunition shells, automobile body
panels
 Also known as deep drawing (to distinguish it from wire and
bar drawing)

Drawing of cup‑shaped part:

 (1) before punch contacts work,
Square or rectangular boxes (as in sinks), Stepped
(2) near end of stroke
cups, Cones, Cups with spherical rather than flat
Starting blank and drawn part bases, Irregular curved forms (as in automobile
shown in lower views body panels)
Drawing of a cup-shaped part is the basic drawing
operation, with dimensions and parameters as
pictured in Figure. A blank of diameter Db is drawn
into a die cavity by means of a punch with diameter
Dp. The punch and die must have corner radii,
given by Rp and Rd. If the punch and die were to
have sharp corners (Rp and Rd = 0), a hole-
punching operation would be accomplished rather
than a drawing operation. The sides of the punch
and die are separated by a clearance c. This
clearance in drawing is about 10% greater than the
stock thickness
c = 1.1 t

Deep drawing animation

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Deep drawing video

https://www.youtube.com/watch?v=y4N2iusS-30
The punch applies a downward force F to accomplish the deformation of the metal, and a downward holding force
Fh is applied by the blankholder, as shown in the sketch.
As the punch proceeds downward toward its final bottom position, the work experiences a complex sequence of
stresses and strains as it is gradually formed into the shape defined by the punch and die cavity. The stages in the
deformation process are illustrated in Figure (2). As the punch first begins to push into the work, the metal is
subjected to a bending operation. The sheet is simply bent over the corner of the punch and the corner of the die, as
in Figure (2). The outside perimeter of the blank moves in toward the center in this first stage, but only slightly.

As the punch moves further down, a straightening action occurs in the metal that was previously bent over the die
radius, as in Figure (3). The metal at the bottom of the cup, as well as along the punch radius, has been moved
downward with the punch, but the metal that was bent over the die radius must now be straightened in order to be
pulled into the clearance to form the wall of the cylinder. At the same time, more metal must be added to replace that
being used in the cylinder wall. This new metal comes from the outside edge of the blank. The metal in the outer
portions of the blank is pulled or drawn toward the die opening to resupply the previously bent and straightened
metal now forming the cylinder wall. This type of metal flow through a constricted space gives the drawing process
its name.
 Measures for the Success of a
Drawing Operation
The ratio of Blank Diameter to Punch
Diameter is Drawing Ratio
The greater the ratio, the more severe the operation…………………….2.0 is the upper limit for this
ratio

Reduction

Blank Diameter – Punch Diameter/ Blank Diameter

The value of reduction should be less than 0.50

Thickness-to-Diameter Ratio

Thickness of starting blank/ Blank Diameter

Should be greater than 1%

To Check Feasibility of a
Drawing Operation
 Other Drawing Operations

Reverse
Redrawing Drawing
Coining

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watch?v=0O5vBVOBv-4
https://www.youtube.com/
watch?v=S1-u-hxrmvo

In coining process, a blank of metal which is softened by

annealing process is placed between two dies containing an
impression. The blank is restricted on its circumference in
such a manner, that upon the two dies closing upon the
blank, the material cannot flow laterally i.e., sideways. The
material is only free to flow upwards (as a result of which it
fills up the depressions in the upper die) and downwards
(when it fills up depressions in the bottom die). The result of
the coining operation is that the design engraved on the top
and bottom dies gets imprinted on the corresponding faces of
the blank in relief (i.e., raised material) without the size of
the blank-circumference changing. Coins used as money in
daily usage are manufactured in this manner. Here forces
required are much higher, enough to cause plastic-flow of
material.
 Embossing

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Sheet metal Embossing is a stamping process for producing raised or sunken designs or relief in sheet metal

https://www.youtube.com/watch?v=WlZlG5f_ldU
 Impact Extrusion vs Deep
Drawing

Impact extrusion is preferable to

deep drawing when
•the component length is more than
twice the diameter.
•the base must be thicker than the side
walls (i.e., a heavy, complex bottom).
•the component geometry incorporates Impact
lugs, bosses, projections, recesses and Extrusion
raised areas.
•the component requires several draws.
Impact extrusion is also superior to deep draw
if there are medium-sized quantities, because
deep draw tooling is very expensive and only
pays off with very high quantities.
Deep
Drawing
 Punch-Dies and Presses for
Sheet Metal Processes
Most press-working operations are performed with conventional punch ‑and ‑die tooling
 Custom‑designed for the particular part
 The term stamping die is sometimes used for high production dies
A press used for sheet metalworking is a machine tool with a
Simple Die stationary bed and a powered ram (or slide) that can be
single blanking operation with each stroke driven toward and away from the bed to perform various
of the press. cutting and forming operations. A typical press, with principal
components labeled, is diagrammed in Figure.
A compound die performs two operations Mechanically or Hydraulically driven
at
a single station, such as blanking and
punching, or blanking and drawing
 Power and Drive Systems

 Hydraulic presses - use a large piston and cylinder to

drive the ram
 Longer ram stroke than mechanical types
 Suited to deep drawing
 Slower than mechanical drives
 Mechanical presses – convert rotation of motor to
linear motion of ram
 High forces at bottom of stroke
 Suited to blanking and punching
 Sheet Metal Operations not
Performed on Presses

Stretch Forming

Stretch forming is a sheet-metal

deformation process in which the
sheet metal is intentionally
stretched and simultaneously
bent in order to achieve shape
change.

(1) start of process;

(2) form die is pressed into the work with force Fdie,
causing it to be stretched and bent over the form.
F- stretching force.
 Sheet Metal Operations not
Performed on Presses

Roll Bending and Roll Forming

Roll bending is an operation in which (usually) large sheet-metal or
plate-metal parts are formed into curved sections by means of rolls.
One possible arrangement of the rolls is pictured here. As the sheet
passes between the rolls, the rolls are brought toward each other to a
configuration that achieves the desired radius of curvature on the work.

Components for large storage tanks and pressure vessels are fabricated
by roll bending. The operation can also be used to bend structural
shapes, railroad rails, and tubes.
A related operation is roll straightening in which nonflat sheets (or other
crosssectional forms) are straightened by passing them between a
series of rolls. The rolls subject the work to a sequence of decreasing
small bends in opposite directions, thus causing it to be straight at the
exit.

Pls don’t forget to explore Contour Roll Forming

 Sheet Metal Operations not
Performed on Presses
Spinning
Spinning is a metal-forming process in which an axially symmetric part is gradually
shaped over a mandrel or form by means of a rounded tool or roller. The tool or roller
applies a very localized pressure (almost a point contact) to deform the work by axial
and radial motions over the surface of the part. Basic geometric shapes typically
produced by spinning include cups, cones, hemispheres, and tubes.
There are three types of spinning operations:
(1) conventional spinning, (2) shear spinning, and (3) tube spinning.
Conventional Spinning
is the basic spinning operation. As illustrated in
Figure, a sheet-metal disk is held against the end of
a rotating mandrelof the desired inside shape of the
final part, while the tool or roller deforms the metal
against the mandrel. The process requires a series
of steps, as indicated in the figure, to complete the
shaping of the part. The tool position is controlled
(1) setup at start of process;
either by a human operator, using a fixed fulcrum
(2) during spinning; and to
(3) completion of process. achieve the required leverage, or by an automatic
 Applications of conventional spinning include
production of conical and curved shapes in low
quantities. Very large diameter parts—up to 5m (15 ft)
or more can be made by spinning.

Alternative sheet-metal processes would require

excessively high die costs.
The form mandrel in spinning can be made of wood or
other soft materials that are easy to shape. It is
therefore a low-cost tool compared to the punch and
die required for deep drawing, which might be a
substitute process for some parts.

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 Sheet Metal Operations not
Performed on Presses
High Energy Rate Forming
Several processes have been developed to form metals using large amounts of
energy applied in a very short time. Owing to this feature, these operations
are called high energy rate forming.

Explosive Forming Electrohydraulic Electromagnetic

Forming /Magnetic Pulse
Forming
To make large parts for aerospace industry

For small size parts due to generation of

small amount of energy

For tubular sheet metal parts

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