DEPARTMENT OF MANUFACTURING AND

MATERIALS

WORKSHOP TECHNOLOGY
MME 1103

METAL FORMING
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Metal Forming

8.1 Metal Forming Equipments

• SHEET METAL with 1mm thickness ( 11.5 cm x 21 cm)
• Protractor
• Steel Ruler
• Scriber
• Steel wire brush
• Engineer’s square
• Round nose pliers
• C-clamp
• Chipping hammer
• Goggles
• Gloves

8.2 Introduction
Forming processes are those processes in which material is plastically deformed to the
desired shape and size. In production the metal forming process is the continuation of
continuous casting or ingots process. Generally the shape of the material before forming
process are either in slab, billet or bloom (Fig. 8.1).

Figure 8.1: Product shape from continuous casting or ingots

Most metal forming process will consist of a die which is a block metal or other hard
material with desired shape to deform the blank (billet, bloom, slab or sheet metal). The
methodology and shape of the die depends on the forming process. Forming processes are
categorized between bulk deformation processes and sheet metal working. Bulk
deformation processes are generally characterized by significant deformations and
massive shape changes and the surface area to volume of the work is relatively small.
Basic operations in bulk deformation (Fig. 8.2) are described as the following;
• Rolling is a process of reducing thickness (or changing the cross section) of a
long workpiece by compressive force applied by a set of rolls.
• Forging is a process in which the workpiece is shaped by compressive forces
applied through various dies and tools which usually performed at elevated
temperatures.

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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Metal Forming

• Extrusion is a process where a billet (round in shape) is forced through a die.

• Drawing is where the diameter of the wire or bar reduced by pulling it through a
die opening.
(Kalpakjian, 2001)

Figure 8.2: Basic bulk deformation processes; (a) rolling (b) forging (c) extrusion and (d)
drawing. Forces are indicated by F and relative motion by v (Courtesy from Groover,
M.P. Fundamentals of Modern Manufacturing, page 436)

Sheet metalworking processes deform material in the shape of metal sheets, strips and
coils. The difference between bulk deformation and sheet metal processes is the surface
area to volume ratio. Sheet metal processes has high surface area to volume ratio. The
operations are often performed as cold working processes using a set of tools called
punch and die. Basic sheet-metal operations are illustrated in Fig. 8.3. The processes
include;

• Bending which involves straining of a metal sheet or plate to take an angle along a
straight axis.
• Drawing refers to the forming of a flat metal sheet into a hollow or concave shape,
such as a cup, by stretching the metal.
• Shearing which is a cutting process and not forming the metal.
(Groover, 1996)

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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Metal Forming

Figure 8.3: Basic sheet metalworking operations; (a) bending (b) drawing and (c)
shearing: (1) contact between punch and the sheet and (2) after cutting. Forces are
indicated by F and relative motion by v (Courtesy from Groover, M.P. Fundamentals of
Modern Manufacturing, page 437)

Advantages of forming processes compare to other type of processes are the production
rate is high and near net-shape forming. However, the equipment is expensive and large
capital expenditure since forming plastically of metal needs large forces. Furthermore the
equipment will have heavy punches (presses) and dies.

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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Metal Forming

8.3 Procedure
1) Study the given drawing and calculate the radius of semicircle
2) Draw a straight line 20 mm above the base line
3) Using the calculated radius, draw a semicircle ( O – A – B)
4) Add another 10 mm to the calculated radius, and draw 2nd semicircle ( O – A’ – B’)
5) Again, using the calculated radius, determine the appropriate angle, θ.
6) By using the formula ( 180 0 - θ ), divide the remaining angle equally and draw a line
( O – C ) and ( O – D )
7) Calculate the radius of small semicircle and draw ( 0 – A” – B” )
8) Draw a line parallel to the line ( O – C ) and ( O – D ) 20 mm and 10 mm down
respectively.( middle line for 20 mm is also drawn )
9) Cut off the marked area by using the snip provided.
10) Fold 10 mm for both parallel lines. One is folded in and another one is out
11) Then, fold the aluminum slowly to the shape of funnel (Fig.8.5) and lock the sides
using the double – seamed locking process
12) From the base, cut a small pieces ( 7 mm ) to the line of semicircle
13) Fold half those pieces carefully using a long nose pliers
14) Curl a given wire and put it inside to those pieces. (Fig. 8.6)
15) Cover the wire using long nose pliers and use punch if necessary
16) Next, calculate the upper and lower tip and draw as figure 1b
17) Finally, lock the sides and place it into the funnel.

3 mm 3 mm

C D

A’ A A” O B” B B’
(b)
20 mm ( thickness : 0.4mm)

( thickness : 0.4mm)
(a)
Figure 8.4: Marking the sheet metal

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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Metal Forming

Figure 8.5: Basic shape of the cone

Figure 8.6: Cross section of section A-A

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MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
Metal Forming

8.4 Project

8.5 Question
1. Name the machine and cutting tool use to cut the sheet metal.
2. Draw the construction of producing the funnel using your Engineering Drawing 1
knowledge.

Reference
1. Groover M.P., (1996), Fundamentals of Modern Manufacturing, Materials,
Processes and Systems, International Editions, Prentice Hall.
2. Gupta J.K. (1996), Basic Workshop Practice, S. Chand & Company Ltd.
3. Kalpakian, S & Schmid, S.R. (2001), Manufacturing Engineering and
Technology – 3rd International Edition, Prentice Hall International.