The document discusses various sheet metal forming processes including shearing, bending, drawing, stretching and special processes like hydroforming, rubber pad forming, and spinning. It covers sheet metal characteristics, typical presses and operations, formability testing methods, and provides details on specific processes like bending, drawing, deep drawing, box drawing, stretch forming, and hydroforming.

1. SHEET METAL PROCESSES
Sheet metal characteristics - Typical shearing operations, bending and
drawing operations – Stretch forming operations –– Formability of sheet
metal – Test methods – Working principle and application of special
forming processes - Hydro forming – Rubber pad forming – Metal
spinning – Introduction to Explosive forming, Magnetic pulse forming,
Peen forming, Super plastic forming.

2. SHEET METAL CHARACTERISTICS
-Roll Forming
-Stretch Forming
-Drawing
-Stamping
-Rubber Forming
-Spinning
-Super Plastic Forming
-Peen Forming
-Explosive Forming
-Magnetic Pulse Forming

3. PRESSES

4. SHEARING OPERATION - BENDING
TYPES OF BENDING OPERATION
- Angle Bending

5. - Angle Bending
- Roll Bending

6. - Roll Forming
If the edges are formed to a desired shape in the form of bend is
made on the sheet metal
- Seaming
The process of providing lock between the two edges of the
different work metal.
SHEARING OPERATION - DRAWING
- Deep Drawing
Length of the part drawn is deeper then width.
- Box Drawing
Length of the part drawn is lesser then width

7. STRETCH FORMING OPERATION
Stretching is the process of stressing the work blank beyond its elastic limit
by moving a form block towards the blank.
FORM BLOCK METHOD

8. FORM BLOCK METHOD
MATING DIE METHOD

9. SPECIAL FORMING PROCESSES
1.0 HYDRO FORMING
1.0 Hydro Forming
2.0 Rubber Pad Forming
3.0 Metal Spinning
a) Hydro Mechanical forming
b) Electro Hydraulic Forming

10. a) Hydro mechanical Forming
b) Electro Hydraulic Forming

11. 2.0 RUBBER PAD FORMING

12. RUBBER HYDROFORMING PROCESS

13. 3.0 METAL SPINNING
a) Manual Spinning
b) Power Spinning

14. EXPLOSIVE FORMING PROCESSES
1.0 Magnetic Pulse Forming Process
2.0 Peen Forming Process
3.0 Super Plastic Forming Process

15. EXPLOSIVE FORMING PROCESSES
- Stand off operations
The explosive charge is located at some distance away from the blank
and energy is transmitted through some fluid medium such as water.
- Contact Operations
The explosive charge is directly located over the blank.

16. 1.0 MAGNETIC PULSE FORMING PROCESS

17. 2.0 PEEN FORMING PROCESS

18. 3.0 SUPER PLASTIC FORMING PROCESS
a) Loading
b) Forming
c) Forming
d) Release

19. BASIC SHEARING OPERATION
1.0 Cutting operations
(a) Blanking

20. BASIC SHEARING OPERATION
1.0 Cutting operations

21. BASIC SHEARING OPERATION
1.0 Cutting operations

22. BASIC SHEARING OPERATION
2.0 Forming operations
(a) Bending
(b) Drawing
(c) Sequeezing
(d) Embossing
(e) Nibbling
It is an operation of cutting any shape from sheet metal
without special tools. It is done on a nibbling machine.

23. FORMABILITY OF SHEETMETAL
Formability = f(f1, f2)
F1 = Material Variables - ductility
F2 = Process Variables – stress system, lubrication, die design etc
Law 1 – Process of fracturing
Ductility of the same material is lower if the section size is large.
Law 2 –Law of geometrical Similitude
1 Blank are geometrically similar to dimension, thickness, width etc.
2 Unit strain at corresponding locations are identical
3 Forces required directly proportional to the square of the thickness
.
4 Consumption of work proportional to the cube of its thickness.

24. FORMABILITY TEST METHOD
1 Formability tests for bulk deformation
Elastic deformation and Plastic deformation
2 Formability test for elastic plastic deformation
1) Tensile test
a) Stretch forming - local thinning
b) Drawing operation – Lower punch by thinning under bi-axial stresses.
2) Simulative tests
a)Erichsen test – Stretchability based on erichsen number
b)Olsen test
c) Swift test - based on blank to punch diameter- drawing ratio
d) Fukui test – both assessed - based on formability index

25. FORMABILITY TEST METHOD
3) Full scale forming test