Sheet Metal Working

1
 SHEET METALWORKING

1. Cutting Operations
2. Bending Operations
3. Drawing
4. Other Sheet Metal Forming Operations
5. Dies & Presses For Sheet Metal Processes
6. Sheet Metal Operations Not Performed On
Presses
7. Bending Of Tube Stock

2
 Sheet Metal Working Defined

Cutting and forming operations performed on relatively

thin sheets of metal
 Thickness of sheet metal = 0.4 mm (1/64 in) to 6 mm (1/4
in)
 Thickness of plate stock > 6 mm
 The sheet or plate stock in metal working is produced by
rolling.
 Operations usually performed as cold working.

3
 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

4
 Advantages of Sheet Metal Parts

 High strength
 Good dimensional accuracy
 Good surface finish
 Relatively low cost
 For large quantities, economical mass production
operations are available
 Cold working is commonly used but for thick
stock,brittle,significant deformation then hot
working is used.

5
Three Major Categories of
Sheet Metal Processes

Cutting
Shearing to separate large sheets; or cut part perimeters or
make holes in sheets
Bending
Straining sheet around a straight axis
Drawing
Forming of sheet into convex or concave shapes

6
 Sheet Metalworking Terminology
7

Presses
Sheet metal operations performed on machine
tools called presses.
Stamping press
Machine tool that performs most sheet metal
operations
Punch‑and‑die
Tooling to perform cutting, bending, and drawing
term stamping die is also used.
Stampings
Sheet metal products
 Cutting
8
1. Cutting of sheet metal is accomplished by a shearing
action between two sharp cutting edges.
2. Upper cutting edge the punch sweeps down past a
stationary lower cutting edge the die.
3. Plastic deformation occurs as punch begins to push
into sheet then penetration occurs and punch
compress sheet and cuts into the metal.
4. Penetration zone is one third of thickness of the
sheet.
5. Fracture is initiated as punch continuous travel
into work.
 Cutting
V=motion F=force
t=stock c=clearance

Figure 20.1

Shearing between two sharp cutting

edges
9
 Characteristics Features of Sheared Edges
10

 Rollover:
Top Of Cut Surface Is A Region Called The Rollover.
 Burnish:
This Result From Penetration Of The Punch Into Work
Before Fracture Began.
 Fractured Zone:
A Relatively Rough Surface Of Cut Edge Where Continued
Downward Movement Of Punch Caused Fracture Of Metal.
 Burr:

A Sharp Corner On The Edge Caused By Elongation of

metal during final separation. Figure 20.2
11
 Shearing, Blanking, and Punching

Three principal operations in pressworking that cut

sheet metal:
Shearing
Blanking
Punching

12
 Shearing

 Sheet metal cutting operation along a straight line

between two cutting edges.
 Typically used to cut large sheets into smaller
sections for subsequent operations performed on a
machine is called a Power Shears or Squaring
Shears.
 The upper blade of power shear is often inclined to
reduce required cutting force.

13
 Blanking and Punching
14

 Blanking - sheet metal cutting to separate piece from

surrounding stock
 Cut piece is the desired part, called a blank

 Punching - sheet metal cutting similar to blanking except

cut piece is scrap, called a slug
 Remaining stock is the desired part

(a) Blanking (b) punching

 Clearance in Sheet Metal Cutting
15

 Distance between the punch and die is called

Clearance “c”.
 Typical values range between 4% and 8% of stock
thickness “t”.
 If too small, fracture lines pass each other, causing
double burnishing and larger force
 If too large, metal is pinched between cutting edges and
excessive burr results
 Clearance can be calculated by following formula
 C=Act C=clearance Ac =Clearance Allowance t=stock
thickness. Table 20.1 clearance allowance value
Too High and Too Low Clearance
16
 Clearance in Sheet Metal Cutting
1

Blanking Punch diameter=Db-2c

Blanking Die Diameter=Db
Hole Punch Diameter= Dh
Hole Diameter=Dh+2c
Angular clearance 0.25° to 1.5°
Cutting Force=F=S t L
F=0.7 T S t L
TS=ultimate tensile strength
Shearing Angle is given to
reduce max. force by using an
angled cutting edged.
Example 20.1 practice urself
 Other Sheet Metal Cutting Operation
18

1. Cut off is shearing operation in which blanks are

separated from a sheet metal strip by cutting opposite
side of part in sequence.
2. Parting involves cutting a sheet metal strip by a punch
with two cutting edges that matches the opposite sides
of blank.
3. Slotting is term used for punching operation that cuts
out elongated or rectangle hole.
4. Perforating involves simultaneous punching of pattern
of holes in sheet metal for decorative purpose or
passage of light & fluid.
Notching
It involves cutting out a portion of metal from the side of
sheet or strip.Seminotching removes a portion of metal
from the interior of sheet.seminotching creates part of
the blank outline, while punching & slotting creates holes
in blank.
Trimming
It is cutting operation performed on a formed part to
remove excess metal and establish size.
Shaving
It is shearing operation performed very small clearance to
obtain accurate dimensions and cut edges that are
smooth and straight. Shaving is performed as secondary
operation after previously cut.

19
Fine Blanking
 It is shearing operation used to blank sheet metal parts
with close tolerances and smooth, straight edges in
one step.
 At start of cycle a pressure pad with a V-shaped
projection applies a holding force Fh against the work
adjacent to punch in order to compress the metal and prevent
distortion.
 Punch then descends with a slower than normal
velocity and smaller clearances to provide the
desired dimensions and cut edges reserved for small stock
thickness.

20
21
 Fine Blanking

22
 Piercing

Slotting

Perforating

26
 Notching

Nibbling

Lancing

27
 Slitting

Parting

Cutoff

28
 Trimming

Shaving Dinking

29
 Dinking

Shaving

30
 Bending
31
Straining sheet metal around a straight axis to
take a permanent bend.
The metal on the inside of neutral plane is
compressed, while outside of neutral plane is
stretched.
Metal is plastically deformed so bend takes
permanent set upon removal of stresses that caused it.
Bending produces little or no change in the
thickness of sheet metal.
Bending operations are performed using punch & die.
The two common bending methods & associated tooling
are V-bending & edge-bending.
(a) Bending of sheet metal
(b) both compression and tensile
elongation of the metal occur in bending

Figure: Nature of a bend in sheet metal

showing tension on the outside and
compression on the inside. (Bottom) The
upper portion of the bend region, viewed
from the side, shows how the center portion
will thin more than the edges.

32
 Types of Sheet metal Bending
V‑ bending : sheet metal is bent between V-shape
punch & die. Angle varies from obtuse to acute.V-
bending is used for low production operations.
Performed on press brake and relatively simple &
inexpensive.

33
 Edge Bending
34

Edge bending involves cantilever loading of sheet

metal. A pressure pad is used to apply force Fh to
hold the base of part against the die, while the
punch forces the part to yield and bend over the edge of
the die & performed with a wiping die more
expensive & complicated used for
Higher production.
 Engineering Analysis of Bending
35

IMPORTANT TERMS BENDING RADIUS R

Bending radius R is
Metal thickness=t normally specified on
Bend angle=α the inside of the part,
Included angle= ά rather than at the neutral
axis. The bending radius
Where α+ ά=180° is determined by the
radius on the tooling
used for bending.
 Bend Allowance
36

Bending Allowance: If the bend radius is small relative to

sheet thickness, the metal tends to stretch during bending. It is
important to be able to estimate the amount of stretching that
occurs so that final part length will match the specified
dimensions. Problem is to determine length of neutral axis
before bending to account for stretching of final bent section.
This length is called bend allowance.
Ab = 2πα(R + Kbat)/360

Where Ab =bend allowance, in. (mm); α=bend angle,

degrees; R = bend radius, in. (mm); t = sheet thickness; and
Kba = factor to estimate stretching. if R < 2t, K ba = 0.33; and if
R>=2t, Kba =0.5.
 Spring Back
37

When the bending pressure is removed at the end

of deformation, elastic energy remains in the
bend part, causing it to recover partially
toward its original shape.
SB = (α–άt )/ άt
Where SB = spring back; α= included angle of
sheet-metal part; άt = included angle of bending
tool, degrees E=modulus of elasticity Y=yield
strength.
 COMPENSATION FOR SPRING BACK
38

 Overbending:the punch angle and radius are fabricated

slightly smaller than the specified angle on the final part so
that sheet metal springs back to desired value.
 Bottoming: involves squeezing the part at the end of the
stroke thus plastically deforming it in the bend region.
 Bending Force: The force required to perform bending
depends on the geometry of the punch and die and the
strength, thickness, and width of the sheet metal. The
maximum bending force can be estimated by means of the
following equation based on bending of a simple beam:
F = (KbfTSwt2)/D
Where F = bending force, lb (N),
TS = tensile strength of the sheet metal, lb/in2. (Mpa);
t = sheet thickness, in. (mm); and
D = die opening dimension.
Kbf =a constant that counts for differences in an actual bending
processes.
For V-bending Kbf =1.33, and for edge bending Kbf =0.33

(a) V-Die
(b) Wiping Die 39
 Other Bending & Forming Operations
40

Flanging is a bending operation edges of sheet metal

part is bent at a 90° usually to form a rim or flange.

Hemming involves bending the edge of sheet over on

itself in more than one bending step. Eliminate sharp
edges, increase stiffness & improve appearance.
 Miscellaneous Bending Operations
41

Seaming: Seaming is a bending operation that can be

used to join the ends of sheet metal in some form
of mechanical interlock.
Curling: also called beading forms the edges of the
part into curl or roll.
Examples:hinges,pots,pans,pocket watch case.
 Miscellaneous Bending Operations
42

a) Channel bending
b) U-bending
c) Air Bending
d) Offset bending
e) Corrugating
f) Tube forming
43
 Drawing
44

 It is sheet metal forming operation used to make cup

shaped, box shaped or complex curved, hollow
shaped parts.
 It is performed by placing a piece of sheet metal over a
die cavity and then pushing the metal into
opening with a punch. Blank hold down flat
against the die by a blank holder.
 Parts include beverage cans, sinks,cooking pots,
automobiles body panels.
 Mechanics of Drawing
Db=blank diameter
Dp=Punch Diameter
Rp & Rd=corner radii of punch &
die
C=clearance =1.1 t
Fh=holding force by blank holder
V=motion of punch
F=punch force

Metal is subjected to
1)Punch makes initial connection
2)Bending operation
3)Straightening operation
4)Friction & compression
5)Final cup shape & thinning
46
 Engineering Analysis of Drawing

Drawing force & holding force are important process

variables ,the starting blank size must be determined.
Measures of Drawing:
Drawing ratio DR is defined for a cylindrical shape as
the ratio of blank diameter Db to punch diameter Dp
DR=Db/Dp approximate value of DR=2.0
Punch & die corner radii limits DR,friction conditions,
depth of draw & characteristics of sheet metal.
Reduction r:
r=Db-Dp/Db r<0.50 DR≤ 2.0
Thickness to dia. ratio (t/Db)=thickness of starting
blank /blank diameter expressed as % grater than 1%.
Drawing Force:
It is required to perform a given operation can be estimated by
formula
F=πDpt(TS)(db/dp-0.7)
F=drawing force t=blank thickness TS=tensile strength Dp&
Dd=blank & punch diameter
Constant 0.7 is a correction factor
Holding Force:
Fh=0.015 Y π{ Db2 – (Dp+2.2t+2Rd)2}
Fh=holding force
Y=yield strength t=thickness Rd=radii corner
Holding force is usually about one third of drawing force.
Blank Size Determination
Correct starting blank diameter is needed large enough to give
complete metal cup shape. Volume of final product is same
as initial blank by setting initial blank volume equal to
final volume of product & solve for dia. Db. Assuming t=0
48
 OTHER DRAWING OPERATIONS
49

Redrawing: If shape change required is very complex

complete forming may require more than one
drawing steps. Second & further drawing steps if
needed referred as redrawing.
For first draw reduction is 40% to 45%
For second draw reduction is 30%.
For third draw reduction is 16%.
50
51
 Reverse Drawing
52

 Reverse drawing in which a drawn part is

positioned facedown on the die so that second
drawing operation produces a configuration such as
shown in fig.20.22.
 Reverse drawing will produce more sever
deformation easier on metal because outside &
inside corners of die in reverse drawing.
 While in redrawing the metal is bent in opposite
direction at two corners, metal experiences less
strain hardening in reverse drawing & drawing force
is lower.
53
 Shapes Other Than Cylindrical Cups

 Square or rectangular boxes (as in sinks),

 Stepped cups,
 Cones,
 Cups with spherical rather than flat bases,
 Irregular curved forms (as in automobile body
panels)
 Each of these shapes presents its own unique
technical problems in drawing

54
 Drawing Without A Blank Holder
One of the primary functions of blank holder is to prevent
wrinkling of the flange while cup is being drawn.
Tendency of wrinkling is reduced as thickness to
diameter ratio of blank increases.
if t/Db ratio is large enough drawing can be accomplished
without a blank holder can be estimated from following
formula Db-Dp< 5t.
 Draw die must have shape of funnel or cone to permit
material to be drawn.
 Lower tooling cost & simple press figure 20.23.
 Separate control of blank holder & punch is avoided .
 Defects in Drawing
56

Sheet metal drawing is more complex operation than

cutting or bending and more things can be wrong. a
number of defects can occur in drawn products some
are given below.
a) Wrinkling in the flange(series of ridges)
b)Wrinkling in the wall
c) Tearing(open crack near base)
d)Earing(irregularities called ears in upper edge)
e) Surface scratches(punch & die not smooth or
insufficient lubrication)
57
58
 Other Sheet Metal Forming Operations

In addition to bending & drawing other operations

are classified as
Operation performed with metal tooling
1. Ironing
2. Coining & Embossing
3. Lancing
4. Twisting
Operation performed with flexible rubber tooling
1. Guerin Process
2. Hydro Forming
 Ironing
60

In deep drawing flange is compressed by

squeezing action of blank perimeter seeking a
smaller circumference as it drawn towards die
opening. Outer edge of blank becomes thicker as it
moves inward.
If thickness of stock is greater then a clearance
b/w the punch & die it will be squeezed to size
of clearance a process known as ironing.
Makes wall thickness of cylindrical cup more
uniform
Examples: beverage cans and artillery shells
Ironing to achieve a more uniform wall thickness in a drawn cup:
(1) start of process; (2) during process
Note thinning and elongation of walls

61
62
 Coining
63

Coining is bulk deformation operation used to form

indentations and raised sections in part.
Indentations are result of thinning of sheet metal &
raised sections result in thickening of metal.
 Embossing
64

Used to create indentations in sheet, such as raised

(or indented) lettering or strengthening ribs.
Operation is similar to coining involves
stretching & thinning.
Embossing dies posses matching cavity
countours,punch contain positive & die contain
negative contour.
Coining dies contain quite different cavities into two
die halves causing more significant metal
deformation than embossing.
 Embossing: (a)
cross‑section of punch
and die configuration
during pressing; (b)
finished part with
embossed ribs

65
 Lancing
66

Lancing is combined with cutting & bending or

cutting & forming operation performed in one step to
partially separate a metal from the sheet.
Lancing is used to make louvers in sheet metal
for venting of heat from interiors of electrical
cabinets.
 67

Twisting
Sheet metal to
tensional loading
rather than a
bending load thus
causing a twist in
sheet over its length.
It is used to make
products such as fan
& propeller blades.
It can be performed
in a conventional
punch & die design to
deform the part in the
required twist shape.
 Rubber Forming Processes
68

Two operations are performed on conventional press

but tooling is unusual in that it uses a flexible
element to effect forming operation. Operations are
Guerin process:
 It uses a thick rubber pad to form sheet metal
over a positive form block. Rubber pad is
confined in a steel container.
 As ram descends rubber gradually surrounds
the sheet applying pressure to deform it to
shape of the form block used relatively shallow form.
 Guerin Process
Advantages of Guerin Process
 Low tooling cost
 Form block can be made of wood, plastic, or other materials that are
easy to shape
 Rubber pad can be used with different form blocks
 Process attractive in small quantity production
 Aircraft industry where process was

developed.

69
 Hydrofroming
70
Similar to Guerin process difference is that rubber
diaphragm is substituted with hydraulic fluid in
place of thick rubber pad.
This allow the pressure that forms the work part to
be increased thus preventing wrinkling deep formed
parts.
Deeper draws can be achieved with hydro form
process than with conventional deep drawing.
Uniform pressure in hydro forming forces the work
to contact the punch throughout its length, increasing
friction & reducing the tensile stresses that cause tearing
at the base of drawn cup.
71
 Dies & Presses For Sheet Metal Processes
72

Punch and die tooling & production equipment used in

conventional sheet metal processing.
Dies:
 Press working operations are performed with
conventional punch and die tooling. The
tooling is referred as a die.
 It is custom designed for a particular part to be
produced.
 The term stamping die is sometime used for
high production dies.
 73

Components of
stamping Die
Punch

Die

Die Set

Punch holder

Die holder

Guide pins & Bushings

Stripper

Stop

Press base

Ram
 Types of stamping Dies
74
Simple Die(single blanking operation)
Compound Die(two operations at single station)
Combination Die (two operations at two different
stations)
Progressive die(two or more operations on sheet metal
coil at two or more stations with each press stroke)
Design of progressive die begins with layout of the part on
strip or coil & determination of which operations are to be
performed at each stations.
The result of this procedure is called strip
development.
 75

Progressive dies
can have dozen or
more stations
Most complicated
& most costly
Economically
justified for
complex parts
Multiple
operations for
higher productions
 Presses
76

A press used for sheet metal working is a machine tool

with a stationary bed and a powered ram that
can be driven toward and away from bed to perform
various cutting & forming operations. A typical press
with components is given below
Frame(control relative position of bed & ram)
Ram is driven by hydraulic & mechanical power
Punch holder is attached to ram
Die holder attached to bolster plate
Presses are available in variety of cpacities,power
system& frame types.
77
 PRESSES
78

The capacity of a press is its availability to deliver the

required force & energy to accomplish the stamping
operation.
Determined by physical size of the press & by
its power system.
Production rate is another important aspect
of capacity.
Press frame are two types
GAP FRAME & STRAIGHT SIDED FRAME
 GAP FRAME PRESS
79

Gap frame has general configuration like letter “C”

often referred to as C-frame.
Provide good access to the die & permit
convenient ejection of stampings or scrap. Gap
frame press are
 Solid Gap Frame
 Adjustable Bed
 Open Back Inclinable
 Press Brake
 Turret Press
80
 Solid Gap Frame
81
Sometime called a gap press has one piece
construction
Presses with this frame are rigid yet C shape
allows convenient access from sides fro feeding
strip or coil stock.
Range of sizes with capacities up to around
1000tons.
Adjustable bed frame press is a variation of
gap frame in which adjustable bed is added to
accommodate various die sizes. Adjustment
feature are scarifies for tonnage.
 Open Back inclined press
82
Open back inclined has a C frame assembled to a base
such a way that frame can be tilted back to various
angles so that stampings fall through the rear opening by
gravity.
Capacities of OBI press range from one ton to 250 tons.
They can be operated at high speed around 1000 strokes
per minute.
Press brake is a gap frame press with a very wide bed.
Allows no. of separate dies(V-bending) to be set up in the
bed so that small quantities of stampings can be made
economically.
Low quantities of parts sometimes requiring multiple
bends at different angles requires manual operations.
83
Turret Presses are suited to situations in which a
sequence of punching, notching and cutting
operations must be accomplished on sheet metal
parts.
Conventional ram & punch is replaced by a turret
containing many punches of different sizes & shapes.
Turret works by indexing (rotating) to the position
holding the punch to perform the required operation.
Beneath the punch turret die turret positions the
die opening for each punch.
Between the punch & die is the sheet metal blank
held by an X-Y positioning system operate by CNC.
Blank is moved to the required coordinate position
for each cutting operations.

84
 Several sheet metal parts
produced on a turret press,
showing variety of hole
shapes possible

CNC Turret Press

85
 Straight sided Frame Presses
86
For jobs requiring high tonnage press frames
with greater structural rigidity are needed.
Straight sided presses have full sides giving it a
box like appearance. This construction increases
the strength & stiffness of frame.
At a result capacities 4000 tons are available
forces in straight sided presses for sheet metal
work used for forging.
In all presses gap frame & straight sided frame size is
closely correlated to tonnage capacity. Larger press
are built to withstand higher in press working. Press
size also related to speed.
87
 Power and Drive Systems

Hydraulic presses - use a large piston and

cylinder to drive the ram
 Longer ram stroke than mechanical types
 Develop full tonnage force through entire stroke

 Suited to deep drawing & other forming operations

 Slower than mechanical drives

 Single action & double action

 Double action presses are useful for deep drawing

 Separately control punch force & blank holder force

88
89
 Mechanical presses
90

Mechanical presses convert rotation of motor to

linear motion of ram
 High forces at bottom of stroke
 Suited to blanking and punching
 Several types includes eccentric,crankshaft,knuckle
joint
 Fly wheel used to store energy of drive motor for
use in stamping operation
 High forces are achieved at bottom of stroke
 Suited to blanking & punching operations
 knuckle joint delivers very high force when it
bottoms often used in coining.
91
92
93
94
 Sheet Metal Operations
Not Performed on Presses

A number of sheet metal operations are not

performed on conventional stamping presses.
1. Stretch forming
2. Roll bending and forming
3. Spinning
4. High‑energy‑ rate forming processes.

95
 Stretch Forming

• Sheet metal is stretched and simultaneously bent to

achieve shape change
• simple & gradual bending is done by gripping by one
or more jaws on each end ,stretched & bent over a
positive die containing the desired form.
• An estimate force is required in stretch forming can be
obtained by multiplying the cross sectional area of sheet
metal in a direction of pulling by the flow stress of the
metal.
F=LtYf
F= force L=Length t=thickness Yf=flow stress of work
metal Fdie= die force by balancing vertical force
components
• More complex contours are possible but limitations on
96
sharp curves.
Stretch forming is widely used in aircraft & aerospace
industries produce large parts in low quantities
characteristics.

Stretch forming: (1) start of process; (2) form die is pressed

into the work with force Fdie, causing it to be stretched and bent
over the form. F = stretching force

97
 Roll Bending

 Roll bending is an operation usually Large metal sheets

and plates are formed into curved sections using rolls
 Rolls are brought towards each other to a
configuration that achieves the desired radius of
curvature on the work.
 Larger storage tanks & pressure vessels are fabricated by
roll bending
 Operation can be used to bend metal plates, structural
shapes, railroads and tubes.
Roll straightening
 Nonflat sheets are straightened by passing them
between a series of rolls.
 Rolls subject to a sequence of decreasing small bends in
opposite directions thus causing it to be straight at the exit.

98
99
 Roll Forming

 Continuous bending process in which opposing

rolls produce long sections of formed shapes from
coil or strip stock.
 Several pairs of rolls are usually required to
produce bending of stock into desired shape.
 Products made by roll forming are
channels,gutters,metal sliding sections,
pipes & tubings,various structural sections.
 Roll forming appearance is like rolling operation
but roll forming involves bending rather than
compressing.

100
 Roll forming of a continuous
channel section:
(1) straight rolls
(2) partial form
(3) final form

101
 Spinning
 Metal forming process in which an axially symmetric
part is gradually shaped over a rotating mandrel
using a rounded tool or roller
 Tool or roller applies a very localized pressure to
deform work by axial & redial motion over surface of part.
 Basic geometric shapes produced by spinning include
cups,cones,hemispheres,tubes,cylinders.
There are three types of spinning operations
1. Conventional spinning
2. Shear spinning
3. Tube spinning

102
 Conventional spinning
103

It is basic spinning operation a sheet metal disk is

held against the end of rotating mandrel of
desired inside shape of final part, while roller
deform the metal against mandrel.
In some cases starting work part is a flat disk.
Process requires a series of steps to complete shaping
of part.
Tool positioned is controlled by human
operator, fixed fulcrum, automatic method like
numerical control. Alternatives are called manual
spinning power spinning.
 Conventional spinning
104
 Power spinning has capability to apply higher forces, faster
cycle time, better process control & greater work size capacity.
 It bends the metal around a moving circular axis to conform the
outside surface of the axisymmetric mandrel.
 Thickness will remain unchanged but diameter of disk is larger
than dia. Of resulting part.
 Applications are conical & curved shaped ,very large diameter
parts.
 Excessive high die cost, mandrel are made of wood,
soft material easy to shape.
 Low cost tool compared to punch & die required for
deep drawing.
Conventional spinning: (1) setup at start of process; (2) during
spinning; and (3) completion of process

105
 Shear Spinning
106

The part is formed over the mandrel by a shear

deformation process in which outside dia.
Remains constant & wall thickness is
reduced.
Flow turning, shear forming, spin forging are other
names.
Applications are aerospace industry such as rocket
nose cones.
Resulting thickness of spun wall is calculated by sine
Law tf=tsinα spinning reduction r=t-tf/t
108
 Tube spinning
109

It is used to reduce the wall thickness and increase the

length of tube by means of rollers applied to work over
cylindrical mandrel.
Tube spinning is similar to shear spinning except
starting work piece is tube rather a flat disk.
Operation can be performed by applying the roller
against work externally or internally.
Also make possible to form profiles in cylinder walls by
controlling the path of roller as it moves tangentially
along the wall.
Thickness can be calculated as in shear spinning.
110
 High‑ Energy‑Rate Forming (HERF)

Processes to form metals using large amounts of

energy over a very short time
HERF processes include:
 Explosive forming
 Electro hydraulic forming
 Electromagnetic forming

112
 Explosive Forming
 Use of explosive charge to form sheet (or plate) metal
into a die cavity
 Work part is clamped & sealed over the die, a vacuum is
created in the cavity beneath.
 Apparatus is placed in a large vessel of water.
 Explosive charge is placed in water at a certain
distance above the work.
 Explosive charge causes a shock wave whose energy is
transmitted to force part into cavity
 Size of explosive charge & distance above cavity as matter of art
& experience.
 Applications: large parts, typical of aerospace industry

113
Explosive forming: (1) setup, (2) explosive is detonated, and
(3) shock wave forms part and plume escapes water surface

114
 Electro Hydro Forming
115
A shock wave is used to deform the work into a
die cavity is generated by discharge of electrical
energy between two electrodes submerged in a
transmission fluid (water).
This process is also called electric discharge forming
Electrical energy is stored in large capacitors &
released to electrodes.
It is similar to explosive forming just with difference of
generating energy.
Smaller amount of heat & energy limits for small parts.
116
 Electromagnetic Forming
 Also called magnetic pulse forming
 Sheet metal is deformed by mechanical force of an
electromagnetic field induced in work part by an
energized coil.
 Coil energized by a capacitor produces a magnetic field.
 Induce field opposes the primary field producing a
mechanical force deforms part into surrounding cavity.
 Developed in 1960s,Presently the most widely used HERF
process
 Applications: tubular parts

117
 Electromagnetic
forming: (1) setup in
which coil is inserted
into tubular work part
surrounded by die; (2)
formed part

118
 Bending Of Tube Stock
119
Several methods of producing tubes & pipes are
discussed previously we examine the method by which
tube are bent & otherwise formed.
Bending of tube stock is more difficult then sheet
stock because a tube tends to collapse & fold when
attempts are made to bend it.
Special flexible mandrel are usually inserted into
tube prior to bending to support the walls during the
operation.
Radius R is defined with respect to the centerline of tube.
Walls inside of bend in compression & outside in
tension
 Bending Methods Of Tubes
121

Stretch bending is accomplished by pulling &

bending of tube around a fixed form block.
Draw Bending is performed by clamping tube
against a form block & then pulling tube through the
bend by rotating the block. Pressure bar is used to
support work as it being bent.
Compression Bending a wiper shoe is used to warp
tube around contour of a fixed form block.
Roll bending associated with forming of sheet stock
also used for bending tubes & other cross sections.
122
123
125
126