Sheet Metal Forming Involves A Wide Range of Processes That Manufacture Parts

Sheet metal forming involves a wide range of processes that manufacture parts
for a vast amount of purposes, both seen and unseen. Sheet metal refers to metal
that has a high surface area to volume ratio. Sheet metal work stock, used for sheet
metal processes, is usually formed by rolling and comes in coils.
A distinction needs to be made between sheet metal and plate metal. Sheet metal is
1/4 inch or less in thickness, while plate is over 1/4 inch in thickness. Sheet and
plate have different applications. Plate is generally used for larger structural parts
like boilers, turbines, bridges and ships. Sheet metal is used in the manufacture of
cars, trains, aircraft, farm equipment, office equipment, furniture, house
appliances, computers, machine components and beverage cans to name a few.
Some of the sheet metal manufacturing processes may be applicable to plate metal
as well, even though the work piece is referenced only as sheet metal. However
plate, particularly thicker plate, will provided its own set of problems in
processing. Therefore, some of the sheet metal operations discussed may not be
applicable to plate.
Sheet metal manufacture is mostly performed on a press and parts are formed
between two die. The top die is called a punch. Sometimes sheet metal parts are
referenced to as stampings. Parts are usually economical and easy to mass produce.
Sheet metal is usually formed cold, however warm or hot working of parts,
(particularly plate), is possible. Generally for sheet metal applications there is
essentially no change, or negligible change, in sheet thickness. For some processes
like deep drawing, there is a slight and expected change in thickness, but this may
also be neglected in most cases. Sheet metal manufacturing produces parts that
typically have high strength, good surface and accurate tolerances.
Sheet Metal Mechanics
And Testing Methods
Mechanical behavior of metal is important to understand when manufacturing
sheet metal products. The metal forming basics section provides information on
this topic. Generally a desirable property for metals is a large plastic deformation
before necking. When necking of the metal occurs, diffuse necking is preferred
over localized necking. A high total elongation of the material before fracture is
also desirable for sheet metal forming. Some metals such as low carbon steels and
aluminum-magnesium alloys may experience yield point elongation. This uneven
yielding of the material may produce stretcher strains or Lueder's bands. These
lines are actually small depressions in the material. Lueder's bands may not be
acceptable in situations where surface finish matters. Grain size, structure and
orientation are also important in a sheet metal work piece. Grains will affect the
properties of the metal as well as surface finish.
In addition to the standard tests for materials, (such as tension tests), there are tests
that are used specifically to determine the formability of sheet metal. One common
test is the cupping test. A specimen is secured over a round die cavity and a steel
ball is pushed into the specimen until fracture of the material occurs. The greater
the distance that the sheet metal can plastically deform before fracture, the greater
the sheet's formability.
Anisotropy is an important factor in sheet metal forming. Anisotropy is the
directional variation of mechanical properties. In other words, the material will
react differently to stress applied in one direction than it would to the same stress
applied in a different direction. If a sheet is isotropic, then its properties are the
same in any direction. Cupping tests can be used to determine anisotropy. If the
fracture occurring due to the applied force through the round ball is circular, then
the sheet is isotropic. If a straight fracture occurs, this means that the sheet is
anisotropic.
Many sheet metal operations will create a complex distribution of forces. Material
elements experience different amounts, and proportions, of bi-axle stress and strain
depending upon their location within the work. Sometimes a sheet metal is tested
over a range of different bi-axle forces. A grid with inscribed circles is printed on
the specimen. The grid and circles will deform with the metal.
Tests can then be performed to determine the metal's reaction to different

combinations of bi-axle strain. Failure and safe zones for combinations of major
and minor, (the two directions), strain can be established. Forming limit diagrams
can then be created to display this information graphically. The forming limit
diagram is a useful reference for sheet metal manufacturers.
Sheet Metal Classification
There are 3 major classes of processes of sheet metal working.
Cutting: Cutting is the use of shearing forces to remove material from a work
piece. Technically not a metal forming process, but of extreme industrial
importance.
Bending: Bending is the forming of a sheet metal work about an axis.
Deep Drawing: Deep drawing is the forming of a cup or box with a flat base
and straight walls, from a sheet metal blank.
Other Processes: Other sheet metal working processes such as ironing,

spinning, rubber forming and high energy rate forming are also discussed in latter
sections.

Sheet Metal Forming Involves A Wide Range of Processes That Manufacture Parts

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Sheet Metal Forming Involves A Wide Range of Processes That Manufacture Parts

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Sheet metal forming involves a wide range of processes that manufacture parts

Tests can then be performed to determine the metal's reaction to different

Bending: Bending is the forming of a sheet metal work about an axis.

Other Processes: Other sheet metal working processes such as ironing,

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