Metal Forming

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 Metal Forming

Topics covered:
Introduction to forming:
Thermo forming:

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 Introduction
Advantages such as :cost effectiveness
Enhanced mechanical properties
Flexible operation
Higher production rate
Considerable material saving
An automobile is supposed to be an assembly of more than 15000
parts.
Manufacturing-conversion of raw material to finished products.
Process:- metal casting metal joining
metal forming metal finishing
metal machining
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 Metal Forming
Applications:- automotive, aerospace, defence and other industries.
Metal forming definition
process of obtaining the required shape and size on the raw material
by subjecting the material to plastic deformation through the
application of tensile force, compressive force, bending or shear force or
combinations of these forces.
Formed products:
wheel rims, car body, valves, rolled shapes for chassis, stamped oil
pan, etc.

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 Metal Forming

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 Metal Forming

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 Metal Forming
Bulk forming processes:
Rolling is a compressive deformation process
Semi finished products:- bars, sheets, etc
Carried out in both hot and cold conditions.

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 Metal Forming
Forging processes:
Open die forging Closed die forming

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 Metal Forming
Extrusion process:
Forward extrusion backward extrusion

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 Metal Forming
Wire Drawing :

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 Metal Forming
Sheet metal operations :

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 Metal Forming
Basic sheet metal operation: Bending

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 Metal Forming

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 Metal Forming
Sequence of sheet metal forming:
1.Blank preparation.
-slitting(Making long sheets into smaller one with knives).
-shearing(sheets are placed in between blades).
2.First forming operations.
-Bending
3.Drawing operations(by using draw dies).
-deep, cup, radial drawing.
4.Subsequent operations.
5.Assembling activities.

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 Metal Forming
Formability Science of Automotive Sheet Panels:
1. materials variables
- (Thickness, mass, tensile strength etc).
2. blank variables
- (size, location, flatness, pre-bend).
3. die variables
- (surface finish, clearance).
4. press variables
-punch speed .
5. other variables-

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 Metal Forming
The main stamping defects analysed by the Formability Theory are as
follows:

1 Splitting in the stamped panel

2. Splitting at the edge of the panel:
3. Wrinkling
4. Shape change:
5. Low stretch
6. Surface soft or low oil canning load
ability.
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 Metal Forming
Example: Limiting dome height.

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 Metal Forming
Thermo Forming:-
Thermoforming is the process where thermoplastic polymer sheet is
heated & deformed into desired shape.
Process :
Heating plastic sheet to the temperature where in softens.
Stretching the softening polymer against a cold mold surface.
Cooling the finished part and trimming excess plastics.

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 Metal Forming

1. Heating :Heating is accomplished by radiant electric heater which is

located by at the distance of 125mm from the sheet.
2. Forming :after heating ,the polymer sheet is converted or formed
into various either air pressure, vacuum or mechanical .So, according
the forming techniques, thermoforming are 3 types.
Vacuum forming
Pressure forming
Mechanical forming

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 Metal Forming
Vacuum forming:-
It is the earliest method of thermoforming.
In vacuum forming, vacuum is created below the preheated plastic
sheet to draw sheet into the cold mold cavity .
The basic steps of vacuum forming are,
1. A flat plastic sheet is heated by radiant heater, which is placed on
one or either side of the plastic of 125mm distance.
2. The softened sheet is placed over a concave cavity.
3. Vacuum draws the sheet to the cold cavity .
4. The product is cooled and extra plastic parts are trimmed.

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Vacuum forming :
Advantage:
1. Operated comparatively low vacuum pressure.
2. Relatively cheap.
Disadvantage:
1. Uneven wall thickness at the corner of the product.
2. Bad finishing or non uniform plastic concentration.
3. Therefore the thinnest area occur at the corner, near the clamp

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 Metal Forming
Pressure Forming:-
Alternative to vacuum forming.
1 .Here, the air pressure is forced to the preheated sheet into cold mold.
Here, the air pressure is much higher than the vacuum forming.
2. The basic difference between vacuum forming is the heated sheet is
pressured from above the mold cavity .
3. Due to high pressure, the heated sheet can be deformed in fraction of
second.(High production rate)

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Pressure forming:
Advantage:
High production rate .
Efficient for large parts.
Low tooling cost.
Disadvantage:
Limited shape complexity.

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 Metal Forming
Mechanical Thermo forming:-
In mechanical forming, air pressure or vacuum pressure do not use to
drag the plastic sheet.
Here, positive(male) and negative (female) molds are brought against
heated plastic sheet, forcing it to the required shape.
Air between the die and sheet is evacuated by using vacuum pump ,
and sheet conforms to the mold shape.
Formed part is cooled and ejected.

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Mechanical thermoforming: (1) heated sheet is placed above a negative

mold, and (2) mold is closed to shape the sheet.
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Mechanical forming
Advantages:
Better dimensional control.
Opportunity for surface detailing of both sides of the parts.
Disadvantages:
Two mold halves are required
Relatively costly.

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 THANK YOU

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