Sheet Metal Forming Processes

SHEET METAL FORMING PROCESSES
What is Sheet Metal?

 A piece of metal whose thickness is between
0.006(0.15 mm) and 0.25 inches(6.35 mm).
 Anything thinner is referred to as a foil and thicker is
considered as a plate.
 Sheet thickness is generally measured in gauge. Greater
the gauge number, thinner the sheet of metal.

 Sheet metal can be cut, bent and stretched into nearly
any shape.
 Generally two types of operations are performed-
forming and cutting.

Sheet Metal Operations: -
 Bending  perforating
 Shearing  Nibbling
 Blanking  Embossing
 Punching  Shaving
 Trimming  Cutoff
 Parting  dinking
 Slitting  Coining
 Lancing  Deep drawing
 Notching  Stretch forming
 Roll forming
Bending
 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.
Press Brake machine
Bending types
Two common bending methods are:
 V-Bending
 Edge bending
 V-Bending: The sheet metal

blank is bent between a V-
shaped punch and die.
 Air bending: If the punch
does not force the sheet to the
bottom of the die cavity,
leaving space or air
underneath, it is called "air
bending“.
 Edge or Wipe Bending:
Wipe bending requires the
sheet to be held against the
wipe die by a pressure pad.
The punch then presses
against the edge of the sheet
that extends beyond the die
and pad. The sheet will bend
against the radius of the edge
of the wipe die.
Bending Operations
Straight flanging Stretch flanging Shrink flanging
Hemming Seaming Curling

Bending Operations
Channel bending U-bending air-bending
Offset-bending Corrugating Tube forming

Shearing
 Shearing is defined
as separating
material into two
parts.
 It utilizes shearing
force to cut sheet

metal.
Blanking
 A piece of sheet
metal is removed
from a larger piece
of stock.
 This removed piece
is not scrap, it is
the useful part.
Fine Blanking
 A second force is
applied underneath the
sheet, directly opposite
the punch, by a
"cushion".
 This technique
produces a part with

better flatness and
smoother edges.
Punching Operations
Punching or Piercing
 The typical punching
operation, in which a
cylindrical punch
pierces a hole into
the sheet.
Blanking & Punching example
Trimming
 Punching away
excess material
from the perimeter
of a part, such as
trimming the
flange from a
drawn cup.
Parting
 Separatinga part
from the remaining
sheet, by punching
away the material
between parts.
Slitting
 Cutting straight
lines in the sheet.
No scrap material
is produced.
Lancing
 Creating a partial
cut in the sheet, so
that no material is
removed. The
material is left
attached to be bent
and form a shape,
such as a tab, vent,
or louver.
Notching
 Punching the edge

of a sheet, forming
a notch in the
shape of a portion
of the punch.
Perforating
 Punching a close
arrangement of a
large number of
holes in a single
operation.
Nibbling
 Punching a series
of small
overlapping slits or
holes along a path
to cut-out a larger
contoured shape.
Embossing
 Certain designs are
embossed on the
sheet metal.
 Punch and die are
of the same
contour but in
opposite direction.
Shaving
Shearing away minimal
material from the
edges of a feature or
part, using a small die
clearance. Used to
improve accuracy or
finish. Tolerances of
±0.025 mm are
possible.
Cutoff
Cutoff - Separating a
part from the
remaining sheet,
without producing
any scrap.
The punch will

produce a cut line
that may be straight,
angled, or curved.
Dinking
Dinking - A
specialized form of
piercing used for
punching soft metals.
A hollow punch,
called a dinking die,
with beveled,
sharpened edges
presses the sheet into
a block of wood or
soft metal.
Coining
 Similarto
embossing with the
difference that
similar or different
impressions are
obtained on both
the sides of the
sheet metal.
Deep Drawing
 Deep drawing is a
metal forming process
in which sheet metal is
stretched into the
desired shape.
 A tool pushes
downward on the sheet

metal, forcing it into a
die cavity in the shape
of the desired part.
Deep Drawing Sequence
Stretch Forming
 Stretch forming is a
metal forming
process in which a
piece of sheet metal
is stretched and bent
simultaneously over
a die in order to form
large bent parts.
Roll Forming
 Roll forming is a
continuous bending
operation in which a long
strip of sheet metal is
passed through sets of
rolls mounted on
consecutive stands, each
set performing only an
incremental part of the
bend, until the desired
cross-section profile is
obtained.
 Roll forming is ideal for
producing constant-profile
parts with long lengths and
in large quantities.
Dies: -
Made up of tool
steel and used to cut
or shape material.
1. Simple die
2. Compound die
3. Combination die
4. Progressive die
Simple Die
 Simple dies or single
action dies perform
single operation for
each stroke of the
press slide.
 The operation may
be one of the cutting

or forming
operations.
Compound Die
 In these dies, two or
more operations may
be performed at one
station.
 Such dies are
considered as cutting
tools since, only
cutting operations are
carried out.
Combination Die
 In this die also , more
than one operation may
be performed at one
station.
 It is different from
compound die in that in

this die, a cutting
operation is combined
with a bending or
drawing operation, due
to that it is called
combination die.
Progressive Die
 A progressive has a
series of
operations.
 At each station , an
operation is
performed on a
work piece during
a stroke of the
press.
Progressive Die
THANK YOU

Sheet Metal Forming Processes

Uploaded by

Copyright:

Available Formats

Sheet Metal Forming Processes

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sheet Metal Forming Processes

Uploaded by

Copyright:

Available Formats

SHEET METAL FORMING PROCESSES

What is Sheet Metal?

the gauge number, thinner the sheet of metal.

forming and cutting.

 V-Bending: The sheet metal

Straight flanging Stretch flanging Shrink flanging

Hemming Seaming Curling

Channel bending U-bending air-bending

Offset-bending Corrugating Tube forming

force to cut sheet

produces a part with

 Punching the edge

The punch will

downward on the sheet

be one of the cutting

compound die in that in

You might also like