Lecture 9 & 10

Lecture 9 & 10
RECAP
Semi- finished products
Further rolling steps
Mill products
SHEET METAL FORMING
Sheet metal forming processes are those in which force is applied to a piece of
sheet metal to modify its geometry rather than remove any material.
The applied force stresses the metal beyond its yield strength, causing the
material to plastically deform, but not to fail. By doing so, the sheet can be
bent or stretched into a variety of complex shapes.
Sheet metal forming processes include the following:

 Bending
 Roll forming
 Spinning
 Deep Drawing
 Stretch forming
 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 in length,
such as a large enclosure or chassis
https://www.custompartnet.com/wu/sheet-metal-forming
Types of Bending
Deep Drawing
 Deep drawing is a metal forming process in which sheet metal is stretched
into the desired part shape.
 A tool pushes downward on the sheet metal, forcing it into a die cavity in
the shape of the desired part.
 The tensile forces applied to the sheet cause it to plastically deform into a
cup-shaped part.
 Deep drawn parts are characterized by a depth equal to more than half of
the diameter of the part.
 These parts can have a variety of cross sections with straight, tapered, or
even curved walls, but cylindrical or rectangular parts are most common.
 Deep drawing is most effective with ductile metals, such as aluminum,
brass, copper, and mild steel.
 Examples of parts formed with deep drawing include automotive bodies and
fuel tanks, cans, cups, kitchen sinks, and pots and pans.
Cutting (Shearing) Operations
In this operation, the work piece is stressed beyond its ultimate strength.
The stresses caused in the metal by the applied forces will be shearing
stresses. The cutting operations include:
 Punching (Piercing)  Lancing
 Blanking  Parting
 Notching  Shaving
 Perforating  Trimming
 Slitting  Fine blanking
Punching & Blanking
 Punching (Piercing): It is a cutting operation by which various shaped holes
are made in sheet metal. Punching is similar to blanking except that in
punching, the hole is the desired product, the material punched out to form the
hole being waste.
 Blanking: Blanking is the operation of cutting a flat shape sheet metal. The
article punched out is called the blank and is the required product of the
operation. The hole and metal left behind is discarded as waste.
https://www.slideshare.net/sahilslideshare/sheet-metalformingprocesses
 Notching: This is cutting operation by which metal pieces are cut from the edge of a
sheet, strip or blank.
 Perforating: This is a process by which multiple holes which are very small and close
together are cut in flat work material.
 Slitting: It refers to the operation of making incomplete holes in a workpiece.
 Lancing: This is a cutting
operation in which a hole is
partially cut and then one side is
bent down to form a sort of tab.
Since no metal is actually
removed, there will be no scrap.
 Parting: Parting involves cutting a
sheet metal strip by a punch with
two cutting edges that match the
opposite sides of the blank.
Terminologies
 Shaving: The edge of blanked parts is generally rough, uneven and unsquare.
Accurate dimensions of the part are obtained by removing a thin strip of metal
along the edges.
 Trimming: This operation consists of cutting unwanted excess material from the
periphery of previously formed components.
 Fine blanking: Fine blanking is a operation used to blank sheet metal parts with
close tolerances and smooth, straight edges in one step.
Steps involved in
Manufacturing
Beverage cans

Lecture 9 & 10 - Sheet Forming

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Further rolling steps

Sheet metal forming processes include the following:

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