Sheet metal is generally less than 6 mm thick and is produced through rolling processes. Common sheet metals include aluminum alloys, copper, stainless steel, brass, and steel. Sheet metal fabrication mainly involves forming processes like bending and cutting processes like blanking, punching, and shearing. Many forming operations can be used on sheet metal like deep drawing, spinning, stretch forming, fine blanking, and roll forming. Sheet metal has applications in industries like automotive, construction, appliances and more.

1. Sheet metal

2. Group members
• M.Salahudin bsme 0111149
• M. Aurangzeb bsme 01113122

3. SHEET METAL
CHARACERSITICS
• Sheet metal is generally less than 6 mm
thick and produced by reducing the
thickness of the raw material by
compressive forces applied through a set
of rolls. The process of rolling began
around 1500. Common sheet metals
include aluminum alloys, copper, stainless
steel, brass, steel, titanium, zinc alloys.

4. FORMABILITY OF SHEET
METAL
• Sheet metal fabrication processes can
mostly be placed into two categories -
forming and cutting. Forming processes
are those in which the applied force
causes the material to plastically deform,
but not to fail. Such processes are able to
bend or stretch the sheet into the desired
shape

5. Formability of Sheet Metal
• Many types of metals are suitable for sheet
metal working depending on their formability:
• Aluminum, copper and their alloys - generally
excellent
• Mild steel and stainless steel generally -
generally fair to excellent
• Nickel and magnesium - generally fair to good

6. BENDING OF SHEET METAL AND
PLATE
• One of the most common metalworking
operation is bending

7. COMMON BENDING OPERATION
• Press break forming
• Sheet metal can bent with simple fixture called
press.this machine use long dies in a
mechanical and it is suitable for small production
.the tooling is simple and adoptable to wide
variety of shapes and the process can be easily
automated die material for most application are
carbon steel or grey iron

8. BEADING
• The edge of the sheet is bent into cavity of
a die .beading also improve the
appearance of the part and eliminate
sharp edge which may be safty hazard

9. FLANGING
• Bending the edge of sheet metal typically
to 90.in shrink flanging the flnge periphery
is subjected to compressive stress if
excessive cause to wrinkle.in streach
flanging the flange is subjected to tensile
stress if excessive cause to cracking and
tearing at the adge

10. HEAMMING
• In hemming process the edge of the sheet
is folded itself heeming increase the
stiffness of the part improve its appeance
and eliminate its sharp edges

11. ROLL FORMING
• This process is used for bending
continues length sheet metal and for large
production run salso called cold roll
forming the metal strip bent in this
operation is passed through the series of
rolls typical product are frames panels .

12. BLANKING
• Blanking is a cutting process in which
a piece of sheet metal is removed
from a larger piece of stock by
applying a great enough shearing
force. In this process, the piece
removed, called the blank

14. Laser cutting
produces part shapes by cutting sheet
material using an intense laser beam. In
CNC laser cutting a beam of high-density
light energy is focused through a tiny hole
in a nozzle. When this beam strikes the
surface of the work piece, the material of
the work piece is vaporized

15. CNC plasma cutting
• is a process of cutting 2D shapes from
sheet metal using a high temperature,
high velocity stream of ionized gas

16. CNC waterjet cutting
• is a process that produces shapes by
cutting sheet material using a high
pressure stream of water containing
abrasive(finishing) particles

17. Photo chemical milling
• is a process that produces 2D part shapes
by creating a chemical resist mask on the
surface of sheet metal and chemically
dissolving material from unmasked areas

18. Band sawing
• creates rough cuts by applying a
continuous-loop saw blade to the material
being cut. Band sawing is often a first step
to other machining processes

19. Shearing ,
• on a conventional straight shears, makes
straight cuts in material of limited
thickness using a scissors-like action

20. CNC turret punching
• creates shapes in sheet material by
successively punching a series of basic
shapes such as circles and rectangles.
The basic shapes are selected from a
rotating turret under CNC control

21. Wire EDM cutting ,
• also known as electrical discharge
machining , is a process that uses an
electrically energized thin wire to slice
through metal. Wire EDM cutting uses
rapid, controlled, repetitive spark
discharges from the wire to the workpiece,
thereby eroding the metal away. The
workpiece must be electrically conductive.

22. • Gear cut by Wire EDM

23. • CNC milling is a cutting process in which
material is removed from a block by a
rotating tool.

24. Countersinking
• creates a V shaped recess near the
surface of a hole.
• Countersinking is often used to recess a
flat head screw or to chamfer hole edges.
The process of countersinking is usually
applied to round holes.
Countersink tool

25. Roll forming
The process is performed on a roll forming line in
which the sheet metal stock is fed through a
series of roll stations. Each station has a roller,
referred to as a roller die, positioned on both
sides of the sheet. The shape and size of the
roller die may be unique to that station, or
several identical roller dies may be used in
different positions. The roller dies may be above
and below the sheet, along the sides, at an
angle,

26. Fine blanking
• IT is a shearing process that produces
parts with a higher quality edge than
conventional blanking. In fine blanking
pressure is applied to both sides of the
part during the shearing action. The image
shows a part made by conventional
blanking (top) and fine blanking (bottom)

27. Fine Blanking Machine

28. Lueders Bands

30. SPINNING
• Spinning, sometimes called spin forming, is a metal
forming process used to form cylindrical parts by rotating
a piece of sheet metal while forces are applied to one
side. A sheet metal disc is rotated at high speeds while
rollers press the sheet against a tool, called a mandrel,
to form the shape of the desired part. Spun metal parts
have a rotationally symmetric, hollow shape, such as a
cylinder, cone, or hemisphere. Examples include
cookware, hubcaps, satellite dishes, rocket nose cones,
and musical instruments
• ,good surface finish low tooling cost but labour unless
automated.

32. Blanking
• The blanking process requires a blanking press,
sheet metal stock, blanking punch, and blanking
die. The sheet metal stock is placed over the die
in the blanking press. The hydraulic press drives
the punch downward at high speed into the
sheet. When the punch impacts the sheet, the
metal in this clearance quickly bends and then
fractures. The blank which has been sheared
from the stock now falls freely into the gap in the
die.

33. 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 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.

34. Deep drawing
• The deep drawing process requires a blank, blank
holder, punch, and die. The blank is a piece of sheet
metal, typically a disc or rectangle, which is pre-cut from
stock material and will be formed into the part. The blank
is clamped down by the blank holder over the die, which
has a cavity in the external shape of the part. A tool
called a punch moves downward into the blank and
draws, or stretches, the material into the die cavity. The
movement of the punch is usually hydraulically powered
to apply enough force to the blank. Both the die and
punch experience wear from the forces applied to the
sheet metal and are therefore made from tool steel or
carbon steel.

35. Can making
Blanking
• Deep drawing
• Re drawing
• Ironing
• Dooming
• Necking
• sceaming

36. Strech 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 contoured parts. Stretch forming is
performed on a stretch press, in which a piece of
sheet metal is securely gripped along its edges
by gripping jaws. The gripping jaws are each
attached to a carriage that is pulled by
pneumatic or hydraulic force to stretch the sheet

37. Stretch forming
• Stretch formed parts are typically large and
possess large radius bends. The shapes that
can be produced vary from a simple curved
surface to complex non-uniform cross sections.
Stretch forming is capable of shaping parts with
very high accuracy and smooth surfaces. Ductile
materials are preferable, the most commonly
used being aluminum, steel, and titanium

39. SHEARING
• The shearing process is performed on a shear machine,
often called a squaring shear or power shear, that can
be operated manually (by hand or foot) or by hydraulic,
pneumatic, or electric power. A typical shear machine
includes a table with support arms to hold the sheet,
stops or guides to secure the sheet, upper and lower
straight-edge blades, and a gauging device to precisely
position the sheet. The sheet is placed between the
upper and lower blade, which are then forced together
against the sheet, cutting the material.

40. PUNCHING
• Punching is a cutting process in which
material is removed from a piece of sheet
metal by applying a great enough
shearing force. Punching is very similar to
blanking except that the removed material,
called the slug, Punching can be used to
produce holes and cutouts of various
shapes and sizes .

41. Tube Bending
• Bending and forming tubes and holllow
sections. They require special tooling to
avoid buckling and folding.

42. Sheet Metal Applications
• Sheet metal is widely used for numerous industrial and
non-industrial applications including:
• Aircraft: Fuselages, wings, body panels, trim parts, etc.
• Automotive : body panels, bumpers, doors, chassis,
trim parts, brackets etc.
• Construction: roofing, home building and structural
applications.
• Other applications: appliances, food and beverage
containers, boilers, kitchen equipment, office equipment
etc.

43. Bracket
chassis