SHEET METAL WORKING

MODULE 3B
BY
Dr. AQUEEL SHAH
ASSOCIATE PROFESSOR
IME
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LEARNING OBJECTIVES
 Sheet Metal Working Definition/Understanding
 Sheet metal working terminologies
 Basic types of sheet metal forming operations
 Cutting/shearing operations
 Punching , blanking
 Cutting , parting
 Slotting , perforating , notching , shaving , trimming , fine blanking
 Bending operation
 Spring back effect
 Variations of bending operations
 Deep drawing
 Types , defects
 Other important sheet metal forming operations
 Equipment /tooling

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INTRODUCTION
 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. Countless everyday
objects are constructed of the material. Thicknesses can vary
significantly, although extremely thin thicknesses are considered
foil or leaf, and pieces thicker than 6 mm (0.25 in) are
considered plate.

 Cutting and forming operations performed on relatively thin sheets

of metal

 Thickness of sheet metal = 0.4mm to 6mm

 Thickness of plate stock > 6mm

 Operations usually performed as cold working

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SHEET AND PLATE METAL PRODUCTS

 Sheet and plate metal parts for consumer and industrial products
such as :
 Automobiles and trucks

 Airplanes

 Railway cars and locomotives

 Farm and construction equipment

 Small and large appliances

 Office furniture

 Computers and office equipment

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ADVANTAGES OF SHEET METAL PARTS

 Comparatively high strength

 Good dimensional accuracy

 Good surface finish

 Relatively low cost


Economical mass production for large quantities

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SHEET METAL WORKING TERMINOLOGIES

 Punch‑and‑die – tooling is used to perform cutting, bending, and

drawing

 Stamping press - machine tool that performs most sheet metal

operations

 Stampings - sheet metal products

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SHEET METAL PROCESSING

 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. Therefore the first step in
any sheet metal process is to cut the correct shape and sized ‘blank’
from larger sheet.

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COLD ROLLING: SHEETMETAL PRODUCTION

www.nzsteel.co.nz

Kalpakjian 8
BASIC TYPES OF SHEET METAL PROCESSES
 Cutting/shearing operation
 Shearing to separate large sheets
 Blanking to cut part perimeters out of sheet metal
 Punching to make holes in sheet metal

 Bending operation
 Straining sheet around a straight axis

 Drawing
 Forming of sheet into convex or concave shapes

 Lets examine these process in detail

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CUTTING/SHEARING PROCESS
 The Shearing process involves cutting sheet metal into individual
pieces by subjecting it to shear stresses in the thickness direction,
typically using a punch and die, similar to the action of a paper
punch.

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BASIC SHEARING OPERATION PICTORIAL
DESCRIPTION

 Shearing of sheet metal between two cutting edges: (1) just before
the punch contacts work; (2) punch begins to push into work,
causing plastic deformation;

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BASIC SHEARING OPERATION PICTORIAL
DESCRIPTION

 Shearing of sheet metal between two cutting edges: (3) punch

compresses and penetrates into work causing a smooth cut
surface; (4) fracture is initiated at the opposing cutting edges
which separates the sheet.

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SHEARING PROCESSES PICTORIAL DESCRIPTION

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CUTTING/SHEARING PROCESS
TYPES

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PUNCHING AND BLANKING

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BLANKING AND PUNCHING PICTORIAL
DESCRIPTION
Blanking - sheet metal cutting to separate piece (called a blank) from
surrounding stock
Punching - similar to blanking except cut piece is scrap, called a slug

(a) Blanking (b) punching.

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PUNCHING AND BLANKING PICTORIAL
DESCRIPTION

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CUTTING AND PARTING

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CUTTING AND PARTING PICTORIAL DESCRIPTION

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SLOTTING , PERFORATING AND NOTCHING

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SLOTTING , PERFORATING AND NOTCHING
PICTORIAL DESCRIPTION

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TRIMMING , SHAVING AND FINE BLANKING

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TRIMMING PICTORIAL DESCRIPTION

PART AFETR TRIMMING

PART WITH OUT TRIMMING
OPEARTION
SHOWING
EXCESSIVE MATERIAL
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SHAVING AND FINE BLANKING PICTORAIL
DESCRIPTION

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FINE BLANKING PICTORIAL DESCRIPTION

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SHAVING PICTORIAL DESCRIPTION

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 SLITTING PICTORIAL DESCRIPTION
 Slitting - It is cutting or shearing along single lines to cut strips from a sheet
or to cut along lines of a given length or contour in a sheet or work piece .

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SHEARING PROCESS TYPES SUMMARY

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SHEARING PROCESS TYPES SUMMARY

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SHEARING PROCESS TYPES SUMMARY

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BENDING

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BENDING
Bending is a process by which metal can be deformed by plastically deforming the material and changing its shape. The material is stressed beyond the yield strength but below
the ultimate tensile strength. The surface area of the material does not change much. Bending usually refers to deformation about one axis. .

α = bend angle
w = width of sheet
R = bend radius
t = sheet thickness 32
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α′ = 180° - α, “included” angle
TYPES OF BENDING
 Two common bending methods are:
 V-bending

 Edge or wipe bending.

 In V-bending the sheet metal blank is bent between a V-shaped

punch and die. The figure below shows a front view and isometric view
of a V-bending setup with the arrows indicating the direction of the
applied force:

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BENDING TYPES PICTORIAL DESCRIPTION

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SPRING BACK IN BENDING

 When the bending stress is removed at the end of the deformation

process, elastic energy remains in the bent part causing it to partially
recover to its original shape. In bending, this elastic recovery is called
spring back. It increases with decreasing the modulus of elasticity, E,
and increasing the yield strength, Y, of a material.

 Spring back is defined as the increase in included angle of the

bent part relative to the included angle of the forming tool after the tool
is removed.

 After spring back:

 The bend angle will decrease (the included angle will increase)
 The bend radius will increase

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SPRING BACK IN BENDING PICTORIAL DESCRIPTION
Following is a schematic illustration of spring back in bending:

αi: bend angle before springback

αf: bend angle after springback
Ri: bend radius before springback
Rf: bend radius after springback

Note: Ri and Rf are internal radii

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SPRING BACK PICTORIAL DESCRIPTION

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COMPENSATION FOR SPRING BACK

 Many ways can be used to compensate for spring back. Two

common ways are:
 Over bending
 Bottoming (coining)

 When over bending is used in V-bending (for example), the punch

angle and radius are fabricated slightly smaller than the specified angle
and radius of the final part. This way the material can “spring back” to
the desired value.

 Bottoming involves squeezing the part at the end of the stroke, thus
plastically deforming it in the bend region.

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 COMPENSATION FOR SPRING BACK PICTORIAL
DESCRIPTION

OVER BENDING
BOTTOMING

ROTARY BENDING
(variation of
over bending)
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VARIATIONS/TYPES OF BENDING
OPERATIONS

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VARIATIONS OF BENDING OPEARTIONS

Other bending operations include:

 Flanging is a bending operation in which the edge of a sheet metal
is bent at a 90° angle to form a rim or flange. It is often used to
strengthen or stiffen sheet metal. The flange can be straight, or it can
involve stretching or shrinking as shown in the figure below :

(a) Straight flanging

(b) Stretch flanging
(c) Shrink flanging

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VARIATIONS OF BENDING OPERATIONS

 Hemming involves bending the edge of the sheet over onto itself in
more than one bending step. This process is used to eliminate sharp
edges, increase stiffness, and improve appearance, such as the edges
in car doors.

 Seaming is a bending operation in which two sheet metal edges are

joined together.

 Curling (or beading) forms the edges of the part into a roll. Curling
is also used for safety, strength, and aesthetics.

(a) Hemming (b) Seaming (c) Curling 42

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VARIATIONS OF BENDING OPERATIONS
 AIR Bending- it is done with the punch touching the work piece
and the work piece not bottoming in the lower cavity

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VARIATIONS OF BENDING OPERATIONS
 Bead Forming- edge of the sheet metal is bent into the cavity of the
die

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VARIATIONS OF BENDING OPERATIONS
 Roll Forming- it is used for bending continues sheets of length of
sheet metal and for large production runs also known as cold roll
forming. Metal strip is bent in stages by passing it through a series
of rolls

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ROLL FORMING PICTORIAL DESCRIPTION

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VARIATIONS OF BENDING OPERATIONS
 Tube Bending - before bending the tube it is packed with sand or
flexible material to avoid buckling and folding. After desire bending
is achieved , the sand is shaken out.

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TUBE BENDING PICTORIAL DESCRIPTION

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DEEP DRAWING AND TYPES

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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. These parts can have a variety of cross sections with
straight, tapered, or even curved walls, but cylindrical or rectangular
parts are most common. 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

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DEEP DRAWING PICTORIAL DESCRIPTION

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DEEP DRAWING PICTORIAL DESCRIPTION

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DEEP DRAWING PICTORIAL DESCRIPTION

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OTHER DRAWING OPERATIONS-REDRAWING

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OTHER DRAWING OPERATIONS-REVERSE DRAWING

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OTHER DRAWING OPERATIONS-DRAWING WITHOUT
BLANK HOLDER

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DRAWING WITHOUT BLANK HOLDER PICTORIAL
DESCRIPTION

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REDRAWING, REVERSE DRAWING AND DRAWING
WITHOUT BLANK PICTORIAL DESCRIPTION

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IRONING

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IRONING PICTORIAL DESCRIPTION

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COMMON DEFECTS IN DRAWING

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DRAWING DEFECTS PICTORIAL DESCRIPTION

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OTHER SHEET METAL WORKING
OPEARTIONS

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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. The tooling used in this process is a stretch
form block, called a form die, which is a solid contoured piece
against which the sheet metal will be pressed. The most common
stretch presses are oriented vertically, in which the form die rests on
a press table that can be raised into the sheet by a hydraulic ram.
As the form die is driven into the sheet, which is gripped tightly at its
edges, the tensile forces increase and the sheet plastically deforms
into a new shape. Horizontal stretch presses mount the form die
sideways on a stationary press table, while the gripping jaws pull the
sheet horizontally around the form die

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STRETCH FORMING PICTORIAL DESCRIPTION

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STRETCH FORMING PICTORIAL DESCRIPTION

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STRETCH FORMING PICTORIAL DESCRIPTION

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BULGING
 A forming operation that increases the diameter of a portion of a
hollow cylindrical part. Bulging also slightly shortens the part, and it
requires the use of a rubber punch or pressurized fluid .

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EMBOSING

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EMBOSING PICTORIAL DESCRIPTION USING RUBBER PADS

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HYDROFORMING
 Hydro forming uses a high pressure hydraulic fluid to press room
temperature working material into a die. To hydro form aluminum
into a vehicle's frame rail, a hollow tube of aluminum is placed inside
a negative mold that has the shape of the desired end result. High
pressure hydraulic pistons then inject a fluid at very high pressure
inside the aluminum which causes it to expand until it matches the
mold. The hydro formed aluminum is then removed from the mold
 Hydro forming is a cost-effective way of shaping malleable metals
such as aluminum or brass into lightweight, structurally stiff and
strong pieces. One of the largest applications of hydro forming is the
automotive industry, which makes use of the complex shapes
possible by hydro forming to produce stronger, lighter, and more
rigid body structures for vehicles
 Generally two main types
 Sheet hydro forming
 Tube hydro forming

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SHEET HYDROFORMING PICTORIAL DESCRIPTION

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SHEET HYDROFORMING PICTORIAL DESCRIPTION

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TUBE HYDROFORMING
 In tube hydro forming pressure is applied to the inside of a tube that is held by dies with
the desired cross sections and forms. When the dies are closed, the tube ends are sealed
by axial punches and the tube is filled with hydraulic fluid. The internal pressure can go up
to a few thousands of bars and it causes the tube to calibrate against the dies. The fluid is
injected into the tube through one of the two axial punches. Axial punches are movable
and their action is required to provide axial compression and to feed material towards the

center of the bulging tube.

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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

 Spinning is typically performed on a manual or CNC lathe and

requires a blank, mandrel, and roller tool. The blank is the disc-
shaped piece of sheet metal that is pre-cut from sheet stock and will
be formed into the part. The mandrel is a solid form of the internal
shape of the part, against which the blank will be pressed .

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SPINNING PICTORIAL DESCRIPTION
 The mandrel and blank are clamped together and secured between the
headstock and tailstock of the lathe to be rotated at high speeds by the
spindle. While the blank and mandrel rotate, force is applied to the sheet by
a tool, causing the sheet to bend and form around the mandrel. The tool
may make several passes to complete the shaping of the sheet. This tool is
usually a roller wheel attached to a lever. The rollers are inexpensive and
experience little wear allowing for low volume production of parts .

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SPINNING TYPES
 There are two distinct spinning methods, referred to as
 Conventional spinning and
 Shear spinning
 Tube spinning
 In conventional spinning- the roller tool pushes against the blank
until it conforms to the contour of the mandrel. The resulting spun
part will have a diameter smaller than the blank, but will maintain a
constant thickness.
 In shear spinning- the roller not only bends the blank against the
mandrel, it also applies a downward force while it moves, stretching
the material over the mandrel. By doing so, the outer diameter of the
spun part will remain equal to the original blank diameter, but the
thickness of the part walls will be thinner
 In tube spinning – the tubes are reduced in thickness by spinning
them on a mandrel using rollers.

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CONVENTIONAL / SHEAR SPINNING PICTORIAL
DESCRIPTION

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CONVENTIONAL / SHEAR SPINNING PICTORIAL
DESCRIPTION

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TUBE SPINNING PICTORIAL DESCRIPTION

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SPINNING PRODUCTS PICTORIAL DESCRIPTION

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HIGH ENERGY RATE FORMING

 It is sheet metal working process which utilizes either , chemical ,

electrical or magnetic source of energy to form desired shape.

 Generally classified into three categories depending upon the

source of energy utilized
 EXPLOSIVE FORMING

 ELECTROHYDRAULIC FORMING

 MAGNETIC FORMING

 High Energy Rate Forming is employed in Aerospace and aircraft

industries and has been successfully employed in the production of
automotive-related component

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EXPLOSIVE FORMING

 High Energy Rate Forming, also known as HERF or explosive

forming can be utilized to form a wide variety of metals, from
aluminum to high strength alloys. In this process the punch is
replaced by an explosive charge. The process derives its name
from the fact that the energy liberated due to the detonation of an
explosive is used to form the desired configuration. The charge
used is very small, but is capable of exerting tremendous forces on
the work piece. In Explosive Forming chemical energy from the
explosives is used to generate shock waves through a medium
(mostly water), which are directed to deform the work piece at very
high velocities.

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EXPLOSIVE FORMING PICTORIAL DESCRIPTION

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ELECTROHYDRAULIC FORMING

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ELECTROMAGNETIC FORMING

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ELECTROHYDRAULIC AND MAGNETIC PULSE
FORMING PICTORIAL DESCRIPTION

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LANCING OPERATION

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