This document discusses various sheet metal forming processes. It covers shearing operations like punching and blanking. It also discusses bending and drawing operations and how they deform sheet metal. Finally, it introduces special forming processes like hydroforming, rubber pad forming, spinning and explosive forming that can form sheet metal into more complex shapes.
1. Sheet metal forming operations include bending, stretching, deep drawing, and other processes where sheets are formed. Bending involves shaping a straight length into a curve and can be done using presses or rolls.
2. Deep drawing uses a die and punch to shape flat sheets into cup-shaped parts. Stretch forming clamps sheet edges and stretches the sheet over a die into the desired shape.
3. Successful forming requires considering the material properties, die and process parameters to avoid defects like cracks, wrinkles, and non-uniform thinning. Minimum bend radii, lubrication, and holding pressure all impact the quality of formed parts.
Sheet metal characteristics – shearing, bending and drawing operations – Stretch forming operations – Formability of sheet metal – Test methods –special forming processes-Working principle and applications – Hydro forming – Rubber pad forming – Metal spinning– Introduction of Explosive forming, magnetic pulse forming, peen forming, Super plastic forming – Micro forming.
The document discusses various metal forming processes. It describes hot working and cold working of metals, where hot working involves shaping metals above their recrystallization temperature and cold working is below this temperature. Specific metal forming processes covered include forging processes like open die forging, closed die forging, and roll forging. Other forming methods discussed are drawing, extrusion, and bending. The advantages and limitations of hot and cold working are also compared.
The document discusses welding symbols according to BS 499 part 2. It provides examples of common welding symbols including types of butt welds like single-V and single-U, supplementary symbols like those indicating non-destructive testing and peripheral welds, dimension symbols showing throat thickness and leg length, multiple staggered weld elements, and other symbols like plug welds and seam welds. The document serves as a reference for interpreting welding symbols specified in BS 499 part 2.
The document discusses abrasive processes and broaching. It describes various abrasive machining processes including grinding, honing and lapping. It details different types of grinding processes such as cylindrical grinding and centerless grinding. It also discusses broaching machines and broaching processes. Broaching involves using a multi-tooth tool to remove material in one pass to produce internal and external features with high tolerances and production rates.
This document discusses metal forming processes. It defines forming and shaping, and provides examples of each. Metal forming involves plastic deformation of material under large external forces to change its shape. The document classifies metal forming processes as cold working, hot working, or warm working based on the temperature of the material. It also discusses properties important for metal forming like ductility and strength. Rolling, forging, extrusion, drawing, and press working are provided as examples of metal forming processes.
This document discusses sheet metal forming processes. It introduces various sheet metal forming methods like bending, stretching, deep drawing, and identifies common defects. The objectives are to describe sheet metal forming processes, discuss variables that affect formability, and emphasize defects and solutions. Various forming equipment, stresses involved, and classifications of sheet metal parts and processes are outlined over several pages.
1. Sheet metal forming operations include bending, stretching, deep drawing, and other processes where sheets are formed. Bending involves shaping a straight length into a curve and can be done using presses or rolls.
2. Deep drawing uses a die and punch to shape flat sheets into cup-shaped parts. Stretch forming clamps sheet edges and stretches the sheet over a die into the desired shape.
3. Successful forming requires considering the material properties, die and process parameters to avoid defects like cracks, wrinkles, and non-uniform thinning. Minimum bend radii, lubrication, and holding pressure all impact the quality of formed parts.
Sheet metal characteristics – shearing, bending and drawing operations – Stretch forming operations – Formability of sheet metal – Test methods –special forming processes-Working principle and applications – Hydro forming – Rubber pad forming – Metal spinning– Introduction of Explosive forming, magnetic pulse forming, peen forming, Super plastic forming – Micro forming.
The document discusses various metal forming processes. It describes hot working and cold working of metals, where hot working involves shaping metals above their recrystallization temperature and cold working is below this temperature. Specific metal forming processes covered include forging processes like open die forging, closed die forging, and roll forging. Other forming methods discussed are drawing, extrusion, and bending. The advantages and limitations of hot and cold working are also compared.
The document discusses welding symbols according to BS 499 part 2. It provides examples of common welding symbols including types of butt welds like single-V and single-U, supplementary symbols like those indicating non-destructive testing and peripheral welds, dimension symbols showing throat thickness and leg length, multiple staggered weld elements, and other symbols like plug welds and seam welds. The document serves as a reference for interpreting welding symbols specified in BS 499 part 2.
The document discusses abrasive processes and broaching. It describes various abrasive machining processes including grinding, honing and lapping. It details different types of grinding processes such as cylindrical grinding and centerless grinding. It also discusses broaching machines and broaching processes. Broaching involves using a multi-tooth tool to remove material in one pass to produce internal and external features with high tolerances and production rates.
This document discusses metal forming processes. It defines forming and shaping, and provides examples of each. Metal forming involves plastic deformation of material under large external forces to change its shape. The document classifies metal forming processes as cold working, hot working, or warm working based on the temperature of the material. It also discusses properties important for metal forming like ductility and strength. Rolling, forging, extrusion, drawing, and press working are provided as examples of metal forming processes.
This document discusses sheet metal forming processes. It introduces various sheet metal forming methods like bending, stretching, deep drawing, and identifies common defects. The objectives are to describe sheet metal forming processes, discuss variables that affect formability, and emphasize defects and solutions. Various forming equipment, stresses involved, and classifications of sheet metal parts and processes are outlined over several pages.
Okay, here are the steps:
1) UTS of 5052-O aluminum = 280 MPa
2) Thickness, t = 1.8 mm
3) Cutting edge length, L = πD = π * 25 mm = 78.5 mm
4) Using the empirical formula:
Fmax = 7.0 * UTS * t * L
= 7.0 * 280 * 1.8 * 78.5
= 3,400 N
So the estimated maximum punch force required is 3,400 Newtons.
This document discusses deep drawing, a sheet metal forming process where a punch is used to push a flat sheet into a die cavity. It describes the typical tool setup, components made via deep drawing like cups and conical shapes, and calculations for blank diameter. Stress patterns in different regions during drawing are explained. Factors affecting drawability and defects in formed components like wrinkling and bottom fracture are also summarized. Formulas for total punch force and drawability ratio are provided. Methods to improve drawability like redrawing and controlling texture are outlined.
This document discusses sheet metal processes and operations. Sheet metal is metal formed into thin, flat pieces that can be cut and bent into various shapes. Common materials for sheet metal include steel, aluminum, copper, and other metals. Key sheet metal operations covered include shearing, blanking/punching, bending, drawing, deep drawing, stamping, and others. Factors that influence these operations such as punch and die design, clearance, and lubrication are also addressed.
Ultrasonic machining (USM) uses high-frequency ultrasonic vibrations to remove material from a workpiece with an abrasive slurry. Key aspects of USM include:
1. An ultrasonic generator and transducer convert electrical energy into high-frequency mechanical vibrations that are transmitted to a tool via a tool holder.
2. An abrasive slurry is passed between the vibrating tool and workpiece to machine the material. Factors like abrasive type and size, slurry concentration, and vibration amplitude influence the material removal rate.
3. Two common transducer types are magnetostrictive and piezoelectric. Piezoelectric transducers are more
The document discusses design considerations for castings. It notes that casting involves pouring molten material into a mold to create complex shapes. Successful casting requires controlling variables like the material, casting method, cooling rate, and gases. The document outlines design considerations like designing parts for easy casting, selecting suitable materials and processes, locating parting lines and gates, and including features like sprues and risers. It also discusses designing parts to avoid defects from things like shrinkage, stress concentrations, and uneven cooling. The document concludes by mentioning some common casting defects and factors in the economics of casting like costs of molds, materials, and production rates.
This document discusses various metal forging processes. It describes how metal forgings can range in size from small parts to parts weighing 700,000 lbs. It lists examples of common forged parts, such as aircraft, automotive, and tool components. The document then discusses specific forging techniques like heading, piercing, sizing, ball forging, ring forging, riveting, coining, and trimming. It notes factors considered in forging analysis like true strain, required force, flow stress, and forging shape factor.
This presentation contains various aspects of metal cutting like mechanics of chip formation, single point cutting tool, chip breakers, types of chips,etc
This document provides an overview of sheet metal forming processes. It discusses both cutting (shearing) operations like punching, blanking, and notching as well as forming operations like bending, drawing, squeezing, and hydroforming. The document describes various bending operations including V-bending, roll bending, and tube bending. It also discusses processes for forming parts like deep drawing, ironing, redrawing, and the multi-step metal forming process used to produce aluminum beverage cans.
This document provides an overview of forging processes and principles. It discusses various forging operations like smith forging, hammer forging, press forging, and roll forging. It also covers forging classification based on temperature (hot, warm, cold forging) and die arrangement (open, closed die forging). Common forging defects and applications in industries like automotive and aerospace are summarized.
Rolling is a metal forming process where metal stock is passed through one or more pairs of rolls to reduce the thickness and change the cross section of the metal. There are both hot and cold rolling processes. The metal is compressed between the rolls through frictional forces, changing the shape of the metal. Rolling processes can produce shapes like plates, sheets, rods, bars, pipes and rails. Rolling mills can have two, three, four or multiple rolls depending on the specific application and required shape. Rolling is used to mass produce metal products and form complex cross sections.
Electrochemical machining (ECM) is a non-traditional machining process that removes metal by electrolysis rather than mechanical forces. In ECM, a tool acts as a cathode and the workpiece as an anode, and an electric current is passed through an electrolyte in the gap between them, chemically dissolving metal from the workpiece. ECM can machine hard metals and complex shapes more accurately than traditional machining. It provides a smooth surface finish with no mechanical forces or heat affecting the workpiece material. However, ECM requires an electrolyte solution, specialized equipment, and produces chemical waste, making it more expensive and less environmentally friendly than other processes.
Pattern allowances are extra material added to patterns to account for shrinkage and other factors during the casting process. Patterns are larger than the final casting size. Allowances include shrinkage allowance for metal contraction, machining allowance for finishing, and draft allowance so patterns can be easily removed from molds. Proper allowances and pattern design can minimize defects and costs in metal casting.
The document discusses the rolling process used in metal forming. It describes rolling as a process where the thickness of metal is reduced by compressive forces from two opposing rolls. Rolling can be used for flat rolling to reduce thickness of rectangular cross-sections or shape rolling to form square cross-sections into shapes like I-beams. The document outlines different types of rolling like hot rolling, cold rolling, continuous rolling and shape rolling and describes the purposes and processes for each type.
Deep drawing is a metal forming process where a flat sheet is formed into a hollow shape using a punch and die. The sheet is placed over the die opening and held in place by a blank holder. The punch then forces the sheet into the die cavity, forming it into the desired shape. Deep drawing can produce complex 3D shapes from sheet metal and offers advantages like high production rates and consistency. However, defects may occur like tearing, wrinkling, thinning, or earing if the process is not controlled properly.
Welding is a fabrication technique that joins materials together by heating them to suitable temperatures using various heat sources like electric arcs or gas flames. There are different types of welding processes categorized by the heat source and filler material used, such as arc welding, gas welding, resistance welding, and solid state welding. The document focuses on three main arc welding processes: shielded metal arc welding uses a consumable electrode covered in flux; gas metal arc welding uses a continuously fed wire electrode and shielding gas; and gas tungsten arc welding uses a non-consumable tungsten electrode and separate shielding gas and filler material. Each process is illustrated and their characteristics are compared. Common welding defects are also briefly discussed.
A brief explanation about the additive manufacturing procedure, this presentation goes through the different varieties of the technology available and the basic working of the same.
This document provides information on bending theory and design principles for bending operations. It discusses the following key points in 3 sentences:
Types of bending covered include V-bending, edge bending, and flanging. Springback occurs as the bent part partially recovers its original shape after bending forces are removed. The document outlines methods to compensate for springback like overbending and bottoming, and provides formulas to estimate springback and calculate bending allowance and force.
Metal forming processes are used to shape metals into useful products. Rolling is the most common forming process and accounts for around 90% of metal forming. It involves passing metal between rolls to reduce thickness or change cross-section. Forging uses dies and compression to shape hot or cold metal. Extrusion forces heated metal through a die to create shapes like rods, tubes and structural sections. Drawing pulls metal through a die to make wires, rods and tubes from both hot and cold workpieces. Deep drawing specifically makes cylindrical parts like cups from sheet metal.
This document discusses the process of solidification in castings. It covers topics including the introduction to solidification, concepts of solidification in castings, solidification of pure metals and alloys, nucleation and growth. Specifically, it describes how solidification begins with the formation of nuclei near the mold walls and progresses through dendritic growth until the entire melt is crystallized. It also discusses solidification curves and phase diagrams for pure metals and alloys.
The document introduces metal forming processes. It defines metal forming as shaping metallic materials through plastic deformation, where the shape changes permanently in contrast to elastic deformation. It describes bulk deformation processes as involving large plastic deformation without changing volume. These include hot working like forging above the recrystallization temperature for easier forming, and cold working like rolling at room temperature for better accuracy. Sheet forming processes change the shape but not the cross-section, operating on thin metal sheets using stamping presses.
The document discusses various sheet metalworking processes including cutting, bending, and drawing. Cutting operations like shearing, blanking, and punching are used to cut sheet metal. Bending involves straining sheet metal around a straight axis using methods like V-bending and edge bending. Drawing forms sheet metal into convex or concave shapes. Key considerations in sheet metalworking are clearance, bending allowances, springback, and forces required for cutting.
This document discusses various sheet metal forming processes including cutting, bending, drawing and other operations. It defines sheet metalworking as including cutting and forming thin sheets of metal between 0.4mm to 6mm thick. Common sheet metal forming processes are described as shearing, blanking, punching, bending and drawing. Factors involved in sheet metal cutting like clearance, punch and die sizes, and estimating cutting forces are also summarized.
Okay, here are the steps:
1) UTS of 5052-O aluminum = 280 MPa
2) Thickness, t = 1.8 mm
3) Cutting edge length, L = πD = π * 25 mm = 78.5 mm
4) Using the empirical formula:
Fmax = 7.0 * UTS * t * L
= 7.0 * 280 * 1.8 * 78.5
= 3,400 N
So the estimated maximum punch force required is 3,400 Newtons.
This document discusses deep drawing, a sheet metal forming process where a punch is used to push a flat sheet into a die cavity. It describes the typical tool setup, components made via deep drawing like cups and conical shapes, and calculations for blank diameter. Stress patterns in different regions during drawing are explained. Factors affecting drawability and defects in formed components like wrinkling and bottom fracture are also summarized. Formulas for total punch force and drawability ratio are provided. Methods to improve drawability like redrawing and controlling texture are outlined.
This document discusses sheet metal processes and operations. Sheet metal is metal formed into thin, flat pieces that can be cut and bent into various shapes. Common materials for sheet metal include steel, aluminum, copper, and other metals. Key sheet metal operations covered include shearing, blanking/punching, bending, drawing, deep drawing, stamping, and others. Factors that influence these operations such as punch and die design, clearance, and lubrication are also addressed.
Ultrasonic machining (USM) uses high-frequency ultrasonic vibrations to remove material from a workpiece with an abrasive slurry. Key aspects of USM include:
1. An ultrasonic generator and transducer convert electrical energy into high-frequency mechanical vibrations that are transmitted to a tool via a tool holder.
2. An abrasive slurry is passed between the vibrating tool and workpiece to machine the material. Factors like abrasive type and size, slurry concentration, and vibration amplitude influence the material removal rate.
3. Two common transducer types are magnetostrictive and piezoelectric. Piezoelectric transducers are more
The document discusses design considerations for castings. It notes that casting involves pouring molten material into a mold to create complex shapes. Successful casting requires controlling variables like the material, casting method, cooling rate, and gases. The document outlines design considerations like designing parts for easy casting, selecting suitable materials and processes, locating parting lines and gates, and including features like sprues and risers. It also discusses designing parts to avoid defects from things like shrinkage, stress concentrations, and uneven cooling. The document concludes by mentioning some common casting defects and factors in the economics of casting like costs of molds, materials, and production rates.
This document discusses various metal forging processes. It describes how metal forgings can range in size from small parts to parts weighing 700,000 lbs. It lists examples of common forged parts, such as aircraft, automotive, and tool components. The document then discusses specific forging techniques like heading, piercing, sizing, ball forging, ring forging, riveting, coining, and trimming. It notes factors considered in forging analysis like true strain, required force, flow stress, and forging shape factor.
This presentation contains various aspects of metal cutting like mechanics of chip formation, single point cutting tool, chip breakers, types of chips,etc
This document provides an overview of sheet metal forming processes. It discusses both cutting (shearing) operations like punching, blanking, and notching as well as forming operations like bending, drawing, squeezing, and hydroforming. The document describes various bending operations including V-bending, roll bending, and tube bending. It also discusses processes for forming parts like deep drawing, ironing, redrawing, and the multi-step metal forming process used to produce aluminum beverage cans.
This document provides an overview of forging processes and principles. It discusses various forging operations like smith forging, hammer forging, press forging, and roll forging. It also covers forging classification based on temperature (hot, warm, cold forging) and die arrangement (open, closed die forging). Common forging defects and applications in industries like automotive and aerospace are summarized.
Rolling is a metal forming process where metal stock is passed through one or more pairs of rolls to reduce the thickness and change the cross section of the metal. There are both hot and cold rolling processes. The metal is compressed between the rolls through frictional forces, changing the shape of the metal. Rolling processes can produce shapes like plates, sheets, rods, bars, pipes and rails. Rolling mills can have two, three, four or multiple rolls depending on the specific application and required shape. Rolling is used to mass produce metal products and form complex cross sections.
Electrochemical machining (ECM) is a non-traditional machining process that removes metal by electrolysis rather than mechanical forces. In ECM, a tool acts as a cathode and the workpiece as an anode, and an electric current is passed through an electrolyte in the gap between them, chemically dissolving metal from the workpiece. ECM can machine hard metals and complex shapes more accurately than traditional machining. It provides a smooth surface finish with no mechanical forces or heat affecting the workpiece material. However, ECM requires an electrolyte solution, specialized equipment, and produces chemical waste, making it more expensive and less environmentally friendly than other processes.
Pattern allowances are extra material added to patterns to account for shrinkage and other factors during the casting process. Patterns are larger than the final casting size. Allowances include shrinkage allowance for metal contraction, machining allowance for finishing, and draft allowance so patterns can be easily removed from molds. Proper allowances and pattern design can minimize defects and costs in metal casting.
The document discusses the rolling process used in metal forming. It describes rolling as a process where the thickness of metal is reduced by compressive forces from two opposing rolls. Rolling can be used for flat rolling to reduce thickness of rectangular cross-sections or shape rolling to form square cross-sections into shapes like I-beams. The document outlines different types of rolling like hot rolling, cold rolling, continuous rolling and shape rolling and describes the purposes and processes for each type.
Deep drawing is a metal forming process where a flat sheet is formed into a hollow shape using a punch and die. The sheet is placed over the die opening and held in place by a blank holder. The punch then forces the sheet into the die cavity, forming it into the desired shape. Deep drawing can produce complex 3D shapes from sheet metal and offers advantages like high production rates and consistency. However, defects may occur like tearing, wrinkling, thinning, or earing if the process is not controlled properly.
Welding is a fabrication technique that joins materials together by heating them to suitable temperatures using various heat sources like electric arcs or gas flames. There are different types of welding processes categorized by the heat source and filler material used, such as arc welding, gas welding, resistance welding, and solid state welding. The document focuses on three main arc welding processes: shielded metal arc welding uses a consumable electrode covered in flux; gas metal arc welding uses a continuously fed wire electrode and shielding gas; and gas tungsten arc welding uses a non-consumable tungsten electrode and separate shielding gas and filler material. Each process is illustrated and their characteristics are compared. Common welding defects are also briefly discussed.
A brief explanation about the additive manufacturing procedure, this presentation goes through the different varieties of the technology available and the basic working of the same.
This document provides information on bending theory and design principles for bending operations. It discusses the following key points in 3 sentences:
Types of bending covered include V-bending, edge bending, and flanging. Springback occurs as the bent part partially recovers its original shape after bending forces are removed. The document outlines methods to compensate for springback like overbending and bottoming, and provides formulas to estimate springback and calculate bending allowance and force.
Metal forming processes are used to shape metals into useful products. Rolling is the most common forming process and accounts for around 90% of metal forming. It involves passing metal between rolls to reduce thickness or change cross-section. Forging uses dies and compression to shape hot or cold metal. Extrusion forces heated metal through a die to create shapes like rods, tubes and structural sections. Drawing pulls metal through a die to make wires, rods and tubes from both hot and cold workpieces. Deep drawing specifically makes cylindrical parts like cups from sheet metal.
This document discusses the process of solidification in castings. It covers topics including the introduction to solidification, concepts of solidification in castings, solidification of pure metals and alloys, nucleation and growth. Specifically, it describes how solidification begins with the formation of nuclei near the mold walls and progresses through dendritic growth until the entire melt is crystallized. It also discusses solidification curves and phase diagrams for pure metals and alloys.
The document introduces metal forming processes. It defines metal forming as shaping metallic materials through plastic deformation, where the shape changes permanently in contrast to elastic deformation. It describes bulk deformation processes as involving large plastic deformation without changing volume. These include hot working like forging above the recrystallization temperature for easier forming, and cold working like rolling at room temperature for better accuracy. Sheet forming processes change the shape but not the cross-section, operating on thin metal sheets using stamping presses.
The document discusses various sheet metalworking processes including cutting, bending, and drawing. Cutting operations like shearing, blanking, and punching are used to cut sheet metal. Bending involves straining sheet metal around a straight axis using methods like V-bending and edge bending. Drawing forms sheet metal into convex or concave shapes. Key considerations in sheet metalworking are clearance, bending allowances, springback, and forces required for cutting.
This document discusses various sheet metal forming processes including cutting, bending, drawing and other operations. It defines sheet metalworking as including cutting and forming thin sheets of metal between 0.4mm to 6mm thick. Common sheet metal forming processes are described as shearing, blanking, punching, bending and drawing. Factors involved in sheet metal cutting like clearance, punch and die sizes, and estimating cutting forces are also summarized.
Sheet metal is a thin piece of metal between 0.006 and 0.25 inches thick. Sheet metal can be cut, bent, and stretched into various shapes through forming and cutting operations. Common forming operations include bending, deep drawing, and roll forming. Common cutting operations include shearing, blanking, punching, notching, and slitting. Sheet metal workers use tools like dies and presses to perform these operations and shape the metal.
Super plastic forming is a metalworking process that uses high temperatures and controlled strain rates to form sheet metal. Materials like titanium alloys and aluminum alloys can elongate several times their original length through this process. Explosive forming also shapes metals through high pressure, using an explosive charge to form sheet metal against a die in either a standoff or contact method. Both processes allow for complex shapes but super plastic forming is slower while explosive forming supports larger parts and shorter production runs.
This document provides guidelines and considerations for designing sheet metal parts that can be efficiently manufactured. It discusses various sheet metal forming processes like blanking, piercing, bending, deep drawing and provides examples of different press tools. It also outlines guidelines for blank and hole design to enable economical manufacturing like minimum section sizes, radii on corners, hole diameters relative to material thickness. Process details covered include principles of plastic deformation and shearing, effects of cutting clearance and calculating flat blank length for bending.
Stretch forming is a sheet metal forming process where a sheet blank is clamped at the edges and formed using a rigid punch. There are several types of stretch forming including simple, tangential, Cyril-Bath, and multi-sided stretch forming. Tangential stretch forming applies a tensile stress before forming for more uniform deformation. The Cyril-Bath process uses grips that move horizontally and vertically to form parts in a press. Multi-sided stretch forming clamps the blank on all sides for complex geometries. Stretch forming is used to produce large, flat parts with low tooling costs.
Sheet metal forming is a versatile manufacturing process used to produce lightweight parts with complex shapes. Common forming operations include punching, blanking, bending, deep drawing, and stamping. Key considerations in sheet metal forming include the material properties, forming limits, stresses induced during forming, and techniques to reduce waste and improve dimensional accuracy. Proper tool and die design is critical for successful forming of sheet metal parts.
This document provides an overview of sheet metal forming processes. It discusses shearing processes like punching and blanking. It describes the effects of clearance between the punch and die on shearing. It also covers other processes like bending, bead forming, flanging, roll forming, and stretch forming. Various press types and die configurations used in sheet metal forming are also summarized.
Explosive forming is a metal shaping technique that uses an explosive charge to generate high forming pressures. There are two main methods - the stand off method places a metal plate over a die and positions an explosive above the plate, while the contact method places the explosive in direct contact with the workpiece. The rapid conversion of the explosive to gas produces a shock wave with pressures up to several million psi that can form metal sheets into complex shapes in a single operation, making it suitable for aerospace applications requiring large or low-quantity customized parts.
The document summarizes the wire drawing process. Wire drawing is used to reduce the cross-sectional area of wire by pulling it through progressively smaller dies. There are single step and continuous wire drawing machines. Proper lubrication is important for smooth finishes and long die life. Different types of dies and materials are used depending on the type of wire. Automation using programmable logic controllers allows maintaining constant speed and drawing force for high accuracy and reduced labor costs.
Sheet metal forming processes Erdi Karaçal Mechanical Engineer University of ...Erdi Karaçal
The document describes various sheet metal forming processes and provides characteristics of each. It discusses roll forming for parts with complex cross-sections and high production rates but high tooling costs. Stretch forming is described as suitable for low quantity production but with high labor costs and tooling/equipment costs depending on part size. Drawing is outlined as having high production rates but also high tooling and equipment costs.
This document describes procedures for conducting a deep drawing test to determine the ductility of sheet metal. The test involves clamping a sheet metal sample at its edges and forcing a conical or hemispherical punch into the sample to form a cup shape. The depth the punch can form before fracture occurs is measured to assess the sample's ductility. The test determines whether a material is suitable for deep drawing processes which shape sheet metal through tensile stretching and compressive forces without cracking.
Plastics are synthetic organic materials that can be molded under heat and pressure into shapes that are retained when the heat and pressure are removed. There are two main types of plastics: thermoplastics, which can be softened and reshaped by reheating, and thermosetting plastics, which undergo a chemical change when heated and hardened that prevents them from being re-softened. Plastic forming involves shaping plastics using molds or frames, with common processes including injection molding, extrusion molding, blow molding, vacuum forming, compression molding, and rotational molding.
This document provides an overview of various sheet metal forming processes. It begins with an introduction to shearing, which involves applying shear stress between a punch and die to cut sheet metal. Key shearing operations like punching, blanking, and progressive dies are described. Other forming methods discussed include bending, deep drawing, stretch forming, spinning, explosive forming, and super plastic forming. Process parameters, equipment, advantages, limitations, and examples of parts made for each technique are summarized. The document provides a comprehensive reference on the different ways sheet metal can be shaped and fabricated.
Plastic manufacturing "forming and shaping plastics"Ayush Mathur
The document discusses various aspects of plastics manufacturing processes. It describes how plastics are formed and shaped through molding, cutting, forming, machining and joining. Some key plastics manufacturing processes discussed include injection molding, blow molding, compression molding, transfer molding, reaction injection molding, extrusion, and thermoforming. The properties of plastic parts are influenced by the manufacturing method and processing parameters used. Large, complex shapes can often be formed as a single unit through these plastic fabrication processes.
This document discusses various sheet metal forming processes and operations. It describes how sheet metal is produced by rolling metal into thin sheets less than 6 mm thick. Common applications of sheet metal include aircraft bodies, automobile bodies, and household utensils. The document outlines various cutting, bending, drawing, and forming operations used to shape sheet metal, including shearing, punching, bending, deep drawing, spinning, and roll forming. It also discusses defects in forming processes and components of dies used in sheet metalworking.
This document provides information about deep drawing and sheet metal forming equipment. It discusses the history and definition of deep drawing, the mechanics and process of drawing, types of deep drawing stations like blanking, drawing, piercing and trimming. It also describes the metal flow during drawing, recommended tool materials, lubrication and cooling methods, common defects, advantages and disadvantages of deep drawing. Different applications of deep drawing in Pakistani industry are highlighted. Comparisons are made between deep drawing and superplastic forming. Finally, various metal forming tools and types of forming dies are explained.
Sheet metal processes involve cutting, bending, and drawing operations. Shearing is the primary cutting operation used to cut sheet metal blanks from large sheets. It involves using a punch and die to cut along a straight line. Bending forms sheet metal by curving it around a straight axis and is done using V-bending or edge bending. Both cutting and bending can result in springback as the sheet tries to return to its original shape after forming. Process parameters like punch and die design, clearance, and lubrication affect the quality of cuts and bends in sheet metal fabrication.
This document discusses various metal forming processes including forging, rolling, drawing, extrusion, and sheet metal forming operations. It provides details on the mechanics and applications of these processes. Key forming processes covered are forging, which uses compressive forces to shape metal; drawing, which reduces the diameter of wires or tubes by pulling them through a die; and extrusion, which forces metal to flow through a die to produce a desired cross-sectional shape. The document also addresses design considerations, lubrication techniques, and common defects in metal forming.
This document provides information about NIEHOFF OF INDIA Pvt. Ltd., a company that manufactures wire drawing machines. It discusses the company's background, facilities, products, manufacturing processes, and key machines used. The company's products include tandem rod breakdown machines, wire annealers, dancer machines, spoolers, and bunchers. The manufacturing process involves steps like sales order processing, engineering, production planning, purchasing, inspection, assembly, and testing. Machines like lathes, grinders, and pneumatic tools are used in assembly.
The document discusses traditional machining processes and tooling. It covers topics like turning, milling, and drilling operations; tool motions; tool life and wear; tool materials; tool geometry; machinability; and productivity optimization. Specifically, it describes three modes of tool failure, the factors that influence tool life, tool wear mechanisms, tool material properties, elements of tool geometry, factors that influence machinability, and formulas for optimizing cutting speed for maximum production rate or minimum unit cost.
Metal sheet forming, its types & operationsUmair Raza
The document discusses various methods of sheet metal forming processes. It introduces stretching, shearing, blanking, bending, deep drawing, and redrawing. It then discusses variables in sheet forming processes and defects that can occur. The document provides classifications of sheet metal parts and describes various forming equipment and machines used. It also details different types of sheet metal forming processes like curling, bending, ironing, laser cutting, hydroforming, punching, progressive forming, rubber hydroforming, spinning, explosive forming, and stretching and deep drawing.
Shearing is a sheet metal forming process where a punch and die are used to cut or punch a part from sheet metal. Key aspects of shearing include the clearance between the punch and die, the shape of the punch and die, and the speed and lubrication used. Other common shearing operations include punching, blanking, die cutting, fine blanking, and slitting. Progressive and transfer dies are also used to perform multiple operations on a sheet metal part in one stroke or between stations. Bending involves applying tensile stresses to the outer fibers of sheet metal to form a curve. Factors like bend allowance, springback, and minimum bend radius must be considered for accurate bending. Deep drawing uses a punch to
Sheet metal processes unit_iv_origional.pptssusera85eeb1
Sheet metal processes involve cutting, bending, and forming thin metal sheets. Common processes include shearing to cut sheets, bending using various dies, drawing to make hollow parts, and stamping using progressive dies. Other specialized processes such as roll forming, spinning, and superplastic forming provide unique shapes through techniques like continuous bending over rolls or stretching over mandrels at high temperatures. A variety of automotive, aircraft, and household goods are produced from sheet metal using these forming techniques.
Tools material cutting for engineering.pptfifihomeless
The document discusses cutting tool geometry and material selection. It states that the two principal aspects to consider in tool selection are geometry and material. The tool geometry must be optimized for the given material and operation, while the tool material must have high strength, resistance and durability against forces, temperatures and wear during machining. The document explains how tool geometry affects chip control, productivity, tool life, cutting forces, and surface quality of the workpiece. It provides details on common tool geometries like rake angle and discusses how tool materials like tungsten carbide, cubic boron nitride and diamonds are suited for different applications based on their properties.
chapter 2 Bulk Deformation Processes in Metal Forming.pptBarsena
This chapter discusses the four basic bulk deformation processes used in metalworking: rolling, forging, extrusion, and wire/bar drawing. It defines each process and explains how they work to change the shape of metal by compressing it into a desired form. Rolling involves squeezing metal between opposing rolls to reduce thickness. Forging uses dies to compress metal into a shaped cavity. Extrusion forces metal through a die opening to produce a uniform cross-section. Wire/bar drawing reduces the diameter of metal rods by pulling them through successive die openings.
This document summarizes various sheet metal processes. It discusses sheet metal characteristics and typical forming operations like shearing, bending, drawing, and stretching. It also covers special forming processes such as hydroforming, rubber pad forming, spinning, explosive forming and super plastic forming. The document provides details on sheet metal tools, presses, cutting and forming operations, factors affecting formability and various test methods used to evaluate formability.
Mp 1-unit - iv - sheet metal processeskarthi keyan
This document discusses various sheet metal processes and forming operations. It describes common sheet metal materials and characteristics. Various presses and cutting dies are discussed for operations like blanking, piercing, and bending. Specific forming processes like drawing, stretching, spinning, hydroforming and magnetic pulse forming are explained. Tests for assessing formability of sheet metals are also summarized.
The document discusses various sheet metal processes and forming techniques. It covers sheet metal characteristics and common operations like shearing, bending, drawing, and stretch forming. It also describes special forming processes such as hydroforming, rubber pad forming, spinning, explosive forming, magnetic pulse forming, and super plastic forming. Test methods for measuring formability are discussed as well. The document provides an overview of the different processes used to work with sheet metals.
The document discusses various sheet metal forming processes. It describes cutting (shearing) operations such as punching, blanking, notching, etc. that stress the metal beyond its ultimate strength. It also discusses forming operations such as bending, drawing, squeezing, etc. that stress the metal below its ultimate strength. Various bending operations like V-bending, roll bending, and bead forming are also covered. The document discusses shearing and compound dies used for cutting operations. It also describes progressive, transfer, and hydroforming dies used for complex forming operations.
The document discusses various sheet metal processes and forming techniques. It covers topics like sheet metal characteristics, typical operations like shearing, bending, drawing and stretching. It also discusses special forming processes like hydroforming, rubber pad forming, spinning, explosive forming and magnetic pulse forming. The document provides details on different presses, cutting and forming operations in shearing. It explains various tests to measure formability of sheet metals.
This document provides an overview of sheet metal forming processes. It begins by describing common applications of sheet metal forming such as metal desks, appliances, and car bodies. It then discusses various sheet metal forming operations like punching, blanking, bending, and deep drawing. The document discusses important sheet metal characteristics like formability, anisotropy, and springback that influence formability. It also summarizes various techniques for cutting, bending, and shaping sheet metal, as well as methods for minimizing scrap.
Testing results of a multi-cavity mold for injection molding of MIM 4140 alloy are presented in the article. Recommendations for manufacturing of forming parts of the mold were given. Based on an implemented technological process of casting and subsequent laboratory researches an information was obtained about the condition of a casting (hardness on Super-Rockwell, shrinkage and quality of a surface layer of material before and after heat treatment). Calculated overall dimensions of the forming parts of the project mold will allow making forecast of shrinkage of MIM 4140 alloy after injection molding.
Sheet metal processes include cutting, forming, and bending operations. Cutting can be done through shearing, punching, or blanking. Forming includes drawing, deep drawing, embossing, stretch forming, spinning, and hydroforming. Bending is done through angle bending, roll bending, or other methods. Special high-energy forming uses explosives, electricity, magnetism, or shot peening to form sheet metal into complex shapes. Properties like grain size, residual stresses, and formability must be considered for different sheet metal forming operations.
Sheet metalworking involves cutting and forming thin metal sheets. There are three main categories of sheet metal processes: cutting, bending, and drawing. Cutting involves shearing metal sheets using sharp blades. Bending forms sheets by curving them around a straight axis. Drawing makes cup-shaped or hollow parts by pushing sheets into shaped dies under high pressure. Additional operations include hole punching, embossing, and specialized processes like spinning, roll forming, and high-energy rate forming. Proper tooling and techniques are needed to produce the many metal parts used in industrial and consumer products.
Ch6 sheetmetw proc Erdi Karaçal Mechanical Engineer University of GaziantepErdi Karaçal
The document discusses sheet metal working processes and focuses on cutting operations like blanking and punching. It describes how sheet metal is cut using punch and die tools on presses. The cutting involves shearing the metal between sharp edges of the punch and die. Process parameters like clearance between the tools and stock thickness determine the cutting forces and quality of cut edges. Techniques like stepped punches and tapered edges can reduce high cutting forces. The document also covers determining the center of pressure for irregular shapes and optimizing scrap strip layout for blanking operations.
super plastic forming- rubber pad formingPravinkumar
1. Super plastic forming is a sheet metal forming process that uses high temperatures and controlled strain rates to achieve very high elongations over 500%. This allows complex shapes to be formed.
2. Electrohydraulic forming uses an electric arc discharge in liquid to rapidly vaporize the surrounding fluid and create a shock wave. This shock wave deforms the workpiece in contact with the fluid inside an evacuated die.
3. Forming limit diagrams are used to test formability by measuring strain after stretching sheet metal samples. The major and minor strains are plotted to determine formability limits.
The document discusses various sheet metal processes and formability testing methods. It covers common sheet metal forming operations like shearing, bending, drawing, and specialized processes such as hydroforming, rubber pad forming, spinning, and super plastic forming. It also describes properties of sheet metals, different types of presses, and factors that influence formability testing methods like the Erichsen and Olsen tests which evaluate formability based on stretchability.
The document discusses various sheet metal processes and formability testing methods. It covers common sheet metal forming operations like shearing, bending, drawing, and specialized processes such as hydroforming, rubber pad forming, spinning, and super plastic forming. It also describes properties of sheet metals, different types of presses, and factors that influence formability testing methods like the Erichsen and Olsen tests which evaluate formability based on metrics like stretchability and drawing ratio.
The document discusses various sheet metal processes and formability testing methods. It covers common sheet metal forming operations like shearing, bending, drawing, and specialized processes such as hydroforming, rubber pad forming, spinning, and super plastic forming. It also describes properties of sheet metals, different types of presses, and factors that influence formability testing methods like the Erichsen and Olsen tests which evaluate formability based on thickness reduction under stress.
Cover Story - China's Investment Leader - Dr. Alyce SUmsthrill
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China’s official organizer of the Expo, CCPIT (China Council for the Promotion of International Trade https://en.ccpit.org/) has chosen Dr. Alyce Su as the Cover Person with Cover Story, in the Expo’s official magazine distributed throughout the Expo, showcasing China’s New Generation of Leaders to the World.
Tired of chasing down expiring contracts and drowning in paperwork? Mastering contract management can significantly enhance your business efficiency and productivity. This guide unveils expert secrets to streamline your contract management process. Learn how to save time, minimize risk, and achieve effortless contract management.
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Business analysis - Prescriptive analytics Introduction to Prescriptive analytics
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1. UNIT IV
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.
1IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
2. • Introduction
• Shearing
• Sheet Metal Characteristics
• Test Methods for Formability
of sheet metals
• Bending sheet and Plate
• Common Bending Operations
• Tube Bending and Forming
• Stretch Forming
• Deep Drawing
• Rubber Forming
• Spinning
• Super Plastic Forming
• Explosive , Magnetic- Pulse, peen,
and Other Forking Processes
• Manufacturing of Honeycomb
Structures
Sheet metal characteristics
2
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
3. Shearing :
• Sheet metal subjected to shear stress developed between
a punch and a die is called shearing
Schematic illustration of
shearing with a punch and
die, indicating some of the
process variables.
Characteristic features of (b)
a punched hole and (c) the
slug. Note that the scales of
the two figures are different.
3
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
4. Shearing
• Shearing usually starts with formation of cracks on
both the top and bottom edges of the work
piece.These cracks meet each other and separation
occurs
Process parameters :
• Shape of the material for the punch and die
• Speed of the punching ,lubrication and clearance
4IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
5. Typical shearing operations
• Several operations based on shearing performed
Punching – sheared slug discarded
Blanking – Slug is the part and the rest is scrap
5IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
6. • Die cutting
• Fine blanking
• Slitting
• Steel rules
• Nibbling
• Scrap in shearing
• Tailor welded blanks
TYPICAL SHEARING
OPERATION
6IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
7. Shearing dies (OPERATIONS):
Clearance : function of type of material,its temper and its
thickness and of the size of the blank and its proximity to
the edges
• Clearance of soft materials are less than harder grades
Punch & die shapes :
• Surfaces of punch and die are flat
• Punch force builds rapidly and entire thickness is
sheared at same time.
7IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
8. Shearing dies
• Fig 16.3 (a) Effect of the clearance,c, between punch
and die in the deformation zone in shearing .As the
clearance increases the material trends to be pulled into
the die rather than be sheared .
8
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
9. Compound dies :
• Several operations on the same strip performed in one
stroke at one station with a compound dies
9
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
10. Progressive dies :
• Parts produced with multiple operations such as, punching, blanking
and notching are made at high production rates in progressive dies.
16.11 (c) Schematic illustration of making a washer in a progressive die
(d) Forming of the top piece of an aerosol spray can in a progressive die.
Note the part is attached to the strip until the last operation is completed
10
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
11. Transfer dies :
• Sheet metal undergoes different operations at different
stations in a straight line or circular path.
11IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER
1.2
12. Other sheet metal cutting methods
• Band saw
• Flame cutting
• Laser beam cutting
• Friction sawing
• Water-jet cutting
12IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
13. Sheet metal characteristics
TYPICAL RANGE OF AVERAGE NORMAL ANISTROPY(Ravg) FOR
VARIOUS SHEET METALS
Table 16.2
Zinc 0.2
Hot rolled steel 0.8-1.0
Cold rolled rimmed steel 1.0-1.35
Cold rimmed aluminum–killed steel 1.35-1.8
Aluminum 0.6-0.8
Copper and Brass 0.8-1.0
Titanium 4-6
13IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
14. Bending and drawing
operations
• Low carbon steels exhibit this behavior
• This produces lueder’s bands(stretch strain marks)
• These marks can be eliminated by reducing thickness of sheet 0.5 % to 1.5
% by cold rolling process
14
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
15. Anisotropy :
• Anisotropy is caused by thermo-mechanical processing
of sheet.
2-types
• Crystallographic anisotropy
• Mechanical fibering
Strains on a tensile-test specimen removed from a piece of sheet metal.These strains
are used in determining the normal and planar anisotropy of sheet metal
15
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
16. Grain size :
• Grain size effects mechanical properties & surface appearance
• The coarser the grain the rougher the appearance
Sheet metal formability :
• Sheet metal undergoes two forms of deformation
• Stretching
• Drawing
16IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
17. Cupping test :
• The sheet metal specimen is clamped between two circular
flat dies and a steel or round punch is pushed hydraulically
into the sheet metal until a crack begins to appear on the
stretched specimen
(a) A cupping test (the Erichsen test) to determine the formability of sheet metals. (b) Bulge-
test results on steel sheets of various widths.The specimen farthest left is subjected
to,basically,simple tension.The specimen farthest right is subjected to equal biaxial
stretching
17
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
18. BENDING OPERATIONS :
• In bending outer fibers are in tension and inner fibers are in
compression
(a) and (b) The effect of elongated inclusions
(stringers) on cracking,as a function of the
direction of bending with respect to the original
rolling direction of the sheet. (c) Cracks on the
outer surface of an aluminum strip bent to an
angle of 90 degree.Note the narrowing of the
top surface due to the Poisson effect
18
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
19. Bend allowance :
• Lb = alf ( R + KT)
Alf – bend angle (radians)
T-sheet thickness
R-bend radius
K-constant
• Bend allowance for ideal case the sheet thickness ;k=0.5
Lb = alf(R+(T/2))
In practice the value of K ranges from 0.33-0.5
• Minimum bend radius
• Engineering strain on a sheet during bending
E = 1 / (2R/T)+1
19IFETCE/MECH/MERGED/II YR/III
SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
20. Spring back :
• In Bending ,after plastic deformation there is an elastic recovery
this recovery is called spring back.
• Spring back can be calculated approximately in terms if radii Ri
and Rf
• Ri/Rf = 4 ( Ri Y / ET )3
– 3 (Ri Y /ET) + 1
Spring back Increases as (R/T ratio & yield stress of material )
increases as elastic modulus E decreases
Spring back in bending .The part tends to
recover elastically after ending,and its
bend radius becomes larger.Under
certain conditions,it is possible for the
final bend angle to be smaller than the
original angle(negative spring)
20
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
21. Cont’d
Compensation for spring back
• Over bending of part
• Bottoming the punch – coin the bend area by
subjecting it to high localized compressive
between the technique tip of the punch and the die
surface.
• Stretch bending – Part is subjected to tension
while being bent.In order to reduce spring back
bending may also be carried to reduce spring back
bending may also be carried out at elevated
temperatures
21IFETCE/MECH/MERGED/II YR/III
SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
22. Bending force :
Maximum bending force, P = KYLT2
W
K – constant ranges from 0.3(wiping die) – 0.7(u-die)-1.3(V-die)
Y – yield stress
L- length of the bend
T- thickness of sheet
For a V-die
Max bending force, P = (UTS)LT 2
W
22IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER
1.2
23. Press brake forming
– Used for sheets 7M(20ft) or longer and other narrow pieces
– Long dies in a mechanical or hydraulic press for small production runs
– Die material range from hardwood to carbides.
23IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER
1.2
24. Roll bending :
– Plates are bent using a set if rolls,various curvatures can
be obtained by adjusting the distance between three rolls
Common die-bending operations,
Showing the die-opening
dimensions, W, used in
calculating bending forces
24
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
25. Beading :
• The periphery if the sheet metal is bent into the
cavity of a die
Bead forming with a single die (b) Bead forming with two dies,in a press
brake
25
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
26. Dimpling :
• First hole is punched and expanded into a flange
• Flanges can be produced by piercing with shaped
punch
• When bend angle < 90 degrees as in fitting conical
ends its called flanging
26IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER
1.2
27. Hemming :
• The edge of the sheet is folded over itself
• This increases stiffness of the part
The metal strip is bent in stages by passing it through a
series of rolls
Seaming :
• Joining two edges of sheet metal by hemming specifically
shaped rollers used for watertight and airtight joints
Stretch forming operations
27IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
28. • Roll forming is used for continuous lengths of sheet metal
• Used for large production runs
Fig: Schematic illustration of the
roll-forming process
Roll forming :
28
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
29. Tube bending and forming
• Special tooling required to avoid buckling and folding
29
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
30. Bulging
• Process involves placing tabular,conical or curvilinear part into a split-
female die and expanding it
30IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
31. Formability of sheet metal
• Individuals are placed inside the parts and mechanically
expanded in radial direction and finally retracted.
Stretch forming
• Sheet metal clamped along its edges and stretched over
a die or form block in required directions.
31IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
32. Stretch forming
Schematic illustration of a stretch forming process. Aluminum
skins for aircraft can be made by this process
32
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
33. Test methods
• Punch forces a flat sheet metal into a deep die
cavity
• Round sheet metal block is placed over a
circular die opening and held in a place with
blank holder & punch forces down into the die
cavity
33
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
34. Deep drawing process :
• Wrinkling occurs at the edges
34IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
35. Deep drawability :
• Deep drawability is expressed in LDR
• Limiting drawing ratio (LDR)
LDR – Max blank dia/punch dia =Do/Dp
• Drawability of metal is determined by normal anisotropy( R )
or plastic anisotropy.
R = width strain / thickness strain =Ew /Et
35IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
36. Working principle and application of
special forming processes
• Edges of cups may be wavy this
phenomenon is called Earing
• The above condition is called
planar anisotropy
• Del R = R0 – 2 R45 + R 90 / 2
Where Del R = 0 => no ears formed
Height of the ears increases Del R
increases.
Earning in a drawn steel cup, caused
by the planar anisotropy of the
sheet metal
36
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
37. Deep drawing Practice :
• Blank holder pressure – 0.7% -1.0 % of Yield strength + UTS
• Clearance usually – 7% -14 % > sheet thickness
• Draw beads are used to control flow of blank into die cavity.
• Ironing is a process in which the thickness of a drawn cup is
made constant by pushing of the cup through ironing rings.
• Redrawing – Containers or shells which are too difficult to
draw in one operation undergo redrawing
37IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
38. • Drawing without blank holder :
Deep drawing without blank holder must be
provided with sheet metal which is sufficiently
thick to prevent wrinkling
Range : Do – Dp < 5T
Hydro forming
38IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
39. • Lowers forces and increases drawability
• commonly used lubricants are mineral oils ,soap
solutions,heavy duty emulsions.
Tooling & equipment for drawing :
• Tool & die materials are tool steels cast irons carbides
• Equipment is hydraulic press or mechanical press
Lubricants
39IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
40. Rubber forming :
• In bending and embossing of sheet metal , the female
die is replaced with rubber pad
Hydro-form (or) fluid forming process :
• The pressure over rubber membrane is controlled
through out the forming cycle ,with max pressure up to
100 Mpi
• As a result the friction at the punch-cup interface
increases ,this increase reduces the longitudinal tensile
stresses in the cup and delays fracture
40
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
41. Rubber pad forming
• Shaping thin sheets by pressing them against a form
with a blunt tool to force the material into a desired
form
• Conventional spinning :
A circular blank if flat or performed sheet metal
hold against a mandrel and rotated ,while a rigid
metal is held against a mandrel and rotated ,wile a
rigid tool deforms and shapes the material over the
mandrel.
41IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
42. Schematic illustration of the conventional spinning process (b) Types of parts
conventionally spun.All parts are antisymmetric
Shear Spinning
42
IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
43. Metal spinning
• Known as power spinning, flow turning, hydro-spinning,
and spin forging
• Produces axisymmetric conical or curvilinear shape
• Single rollers and two rollers can be used
• It has less wastage of material
• Typical products are rocket-
motor casing and missile
nose cones.
43IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
44. Tube spinning :
• Thickness of cylindrical parts are reduced by spinning
them on a cylindrical mandrel rollers
• Parts can be spun in either direction
• Large tensile elongation up to 2000 % are obtained within
certain temperature ranges and at low strain rates.
44IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
45. Super Plastic forming :
Advantages :
• Lower strength is required and less tooling costs
• Complex shapes with close tolerances can be made
• Weight and material savings
• Little or no residual stress occurs in the formed parts
Disadvantages :
• Materials must not be super elastic at service
temperatures
• Longer cycle times
45IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
46. Introduction to Explosive forming
• Explosive energy used s metal forming
• Sheet-metal blank is clamped over a die
• Assembly is immersed in a tank with water
• Rapid conversion of explosive charge into gas generates a shock
wave .the pressure of this wave is sufficient to form sheet metals
46IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
47. Peak pressure (due to explosion):
caused due to explosion , generated in water
P = k( 3sqrt(w) /R)9
P- in psi
K- constant
TNT- trinitrotoluene
W-weight of explosive in pounds
R- the distance of explosive from the work piece
47IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
48. Diffusion Bonding and Superplastic
Forming
48IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
49. Magnetic
pulse forming
• Suranaree University of Technology Jan-Mar 2007
• Stretch formiing
• • Forming by using tensile forces
• to stretch the material over a tool
• or form block.
• • used most extensively in the
• aircraft industry to produce parts
• of large radius of curvature.
• (normally for uniform cross
• section).
49IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
50. Peen forming
• Known as power spinning, flow turning, hydro-spinning,
and spin forging
• Produces axisymmetric conical or curvilinear shape
• Single rollers and two rollers can be used
• It has less wastage of material
• Typical products are rocket-
motor casing and missile
nose cones.
50IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2
51. Super plastic forming.
Maximum bending force, P = KYLT2
W
K – constant ranges from 0.3(wiping die) – 0.7(u-die)-1.3(V-die)
Y – yield stress
L- length of the bend
T- thickness of sheet
For a V-die
Max bending force, P = (UTS)LT 2
W
51IFETCE/MECH/MERGED/II YR/III SEM/ME2201/MTI/PPT/UNITIV/VER 1.2