This document discusses various sheet metal processing techniques. Sheet metal can be cut and bent into different shapes from thin, flat metal pieces. Common sheet metal operations include cutting through techniques like shearing, blanking, punching, notching, perforating, slitting, and lancing. Forming techniques shape the metal and include bending, roll forming, spinning, deep drawing, and stretch forming. Each technique is described in one or two sentences with examples provided for some methods.

2. SHEET METAL PROCESSING
WAQAS AHMED
BS Mechanical Engineering

3. SHEET METAL PROCESS

Sheet metal is simply metal formed into thin
and flat pieces. It is one of the fundamental
forms used in metalworking, and can be cut
and bent into a variety of different shapes.

4. SHEET METAL

The raw material for sheet metal
manufacturing processes is the output of the
rolling process. Typically, sheets of metal
are sold as flat, rectangular sheets of
standard size. If the sheets are thin and very
long, they may be in the form of rolls

5. TYPES OF OPERATION
Before deciding on the processes), one
should determine whether a particular
sheet metal can be formed into the
desired shape without failure. The sheet
metal operations done on a press may
be grouped into two categories.

I ) cutting(shearing)

ii ) forming

6. SHEET METAL OPERATIONS





Bending
Roll forming
Spinning
Deep Drawing
Stretch forming
Forming operation
Shearing
 Blanking
 Piercing
 Notching
 Perforating
 Slitting
 Lancing

Cutting operation

7. 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.

8. BENDING TYPES
V-bending
 Air Bending


9. BENDING TYPES

Rotary Bending

Wiping Die

10. 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.

11. ROLL FORMING

12. 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.

13. SPINNING

14. 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.

15. DEEP DRAWING

16. 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 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.

17. STRETCH FORMING

18. SHEARING

Shearing, also known as die cutting is a
process which cuts stock without the
formation of chips or the use of burning or
melting. Strictly speaking, if the cutting
blades are straight the process is called
shearing; if the cutting blades are curved
then they are shearing-type operations.

19. SHEARING

20. BLANKING
 Blanking
is the operation of cutting a
flat shape from sheet metal. The
product punched out is called the
“blank” and the required product of
the operation the hole and the metal
left behind is discarded as waste.

21. BLANKING

22. PUNCHING OR 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 from the hole
being .

23. PUNCHING OR PIERCING

24. NOTCHING

Notching is a metal-cutting process used on
sheet metal or thin bar stock, sometimes on
angle sections or tube. A shearing or
punching process is used in a press, so as to
cut vertically down and perpendicular to the
surface, working from the edge of a work
piece.

25. NOTCHING

26. PERFORATING

A perforation is a small hole in a thin
material or web. There is usually more than
one perforation in an organized fashion,
where all of the holes are called
a perforation. The process of creating
perforations is called perforating, which
involves puncturing the work piece with
a tool.

27. PERFORATING

28. SLITTING PROCESS
 Slitting
is a process of cutting larger
width coils into narrower width coils
with repetitive accuracy at a high
speed.

29. SLITTING PROCESS

30. LANCING
 Lancing
is a punching operation in
which the work piece is sheared and
bent with one strike of the die. A key
part of this process is that there is not
reduction of material, only a
modification in its geometry. This
operation is used to make tabs, vents.

31. LANCING