Sheet metal working

Sheet metalworking processes are forming and cutting operations performed on metal sheets, strips, and coils. The surface area-to-volume ratio of the starting metal is high; thus, this ratio is a useful means to distinguish bulk deformation from sheet metal processes. Press working is the term often applied to sheet metal operations because the machines used to perform these operations are presses (presses of various types are also used in other manufacturing processes).A part produced in a sheet metal operation is often called a stamping. Sheet metal operations are always performed as cold working processes and are usually accomplished using a set of tools called a punch and die. The punch is the positive portion and the die is the negative portion of the tool set

Sheet metal working

The basic sheet metal operations are defined as follows: _ Bending. Bending involves straining of a metal sheet or plate to take an angle along a (usually) straight axis.

Figure 16.16 Bending terminology. Note that the bend radius is measured to the inner surface of the bent part.

Sheet metal working

Drawing. In sheet metalworking, drawing refers to the forming of a flat metal sheet into a hollow or concave shape, such as a cup, by stretching the metal. A blank holder is used to hold down the blank while the punch pushes into the sheet metal.
(a) Drawing of cup-shaped part: (1) before punch contacts work, (2) near end of stroke; (b) workpart: (1) starting blank, (2) drawn part.

Sheet metal working

Shearing This process seems somewhat out-of-place in a list of deformation processes, because it involves cutting rather than forming. A shearing operation cuts the work using a punch and die.

Figure 16.2 (a) 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: The scales of the two figures are different.)

Die-Cutting Operations

Figure 16.4 (a) Punching (piercing) and blanking. (b) Examples of various die-cutting operations on sheet metal.

Sheet metal cutting operations

Blanking Blanking operation is a process in which the punch is used to remove a portion of material from the stock which is the strip of necessary thickness and width. The removed portion is called blank. Piercing It is also known as punching. The piercing is making hole in a sheet. It is identical to blanking except of the fact the punchout portion coming out to the die in piercing is scrap. Punching : it is the process of making holes in the blank material

Sheet metal cutting operations

Trimming : it is an operation used to remove excess metal, irregular outlines and wavy edges etc from the wall of the drawn component.

Sheet metal operations

Notching same as piercing edge of the strip or black forms part of the punch-out perimeter Nibbling Produces a series of overlapping slits/notches Shaving finishing operation in which a small amount of metal is sheared away from the edge of an already blanked part can be used to produce a smoother edge

Sheet metal cutting opeations

CUT OFF Punch and die operation used to separate a stamping or other product from a strip or stock

Sheet metal cutting operations

Dinking Used to blank shapes from low-strength materials such as rubber, fiber and cloth.

Sheet metal cutting operations

Schematic illustrations of the shaving process. (a) Shaving a sheared edge. (b) Shearing and shaving combined in one stroke.

Sheet metal cutting operations

Perforating in this operation multiple holes which are very small and close together are cut in flat work material Slitting it is the operation of making an unfinished cut through a limited length only Lancing lancing consits of cutting the sheet metal through a small length and bending this small cut portion downwards

Sheet metal forming operations

Sheet metal forming operation Bending Drawing Squeezing Embossing Nibbling

Sheet metal forming operations

Bending In bending the metal is stressed in both tension and compression at the elastic limit but below the ultimate strength of the Metal. When the metal is loaded beyond the elastic limit it undergoes some plastic deformation but when load is removed the metal retain the bent shape. There is some amount of elastic recovery resulting in slight opening up of the bent. This phenomenon is called as spring back. To avoid it the metal should be over bent by such that in the pressure is released part should return in its correct shape.

Sheet metal forming operations

Springback The elastic recovery of the material after unloading of the tools

To compensate with the unbending action of the springback, the metal should be slightly overbent.

Sheet metal forming operations

Classifications of Bending Processes Angle Bending straightening Roll Forming Draw and Compression bending Seaming Roll Flanging

Bending operations
Roll Bending Bending where plates, sheets and rolled shapes can be bent to a desired curvature Roll bending toll can bend plate up to 6 inches thick Angle Bending

Sheet metal forming operations Drawing Bending Work piece is clamped against a bending form and the entire assemble rotates to draw the workpiece across a stationary

Sheet metal forming operations Compression Bending The bending form remains stationary and the pressure tool moves along the work piece

Bending operations
Roll Forming Involves the progressive bending of metal strip as it passes through a series of forming rolls Any material that can be bent can be roll- formed

Bending operations

Bending operations

Seaming - bending operation that can be used to join the ends of sheet metal to form containers such as cans, pails and drums Roll Forming - involves the progressive bending of metal strip as it passes through a series of forming rolls Any material that can be bent can be roll- formed

Bending operations
Flanging -the process of rolling on sheet metal in essentially the same manner as seaming

Roll- straightening/ Roll Leveling -subjects the material to a series of reverse bend -metal is bent back and forth

Drawing and Sheet Metal Forming

Bar drawing and wire drawing

Drawing is an operation in which the cross section of a bar , rod wire is reduced by pulling it through a die opening as in figure . The general features of the process are similar to those of extrusion . The difference is that the work is pulled through the die in drawing, whereas it is pushed through the die inn extrusion . Although the presence of tensile stresses is obvious in drawing, compression also plays a significant role because the metal is squeezed down as it passes through the die opening. The term wire and bar drawing is used to distinguish the drawing process discussed here from the sheet metal process of the same name. The basic difference between bar drawing and wire drawing is he stock size that is processed. Bar drawing is he term used for large diameter bar and rod stock, while drawing applies to small diameter stock. Wire size down to 0.03mm are possible in wire drawing. Although the mechanics of the process are the same for the tow cases , the methods, equipment, and even the terminology are some what different.