1. Rico Ferdiansyah Pradana (160515510210) D3 T.

O/Off-D
2. Rahaldi Bagus (160515510208) D3 T.O/Off-D
METAL FORMING PART II
So, the very first thing that the man tries to show in the video is bending tubing. The
video is showing how one inch or half inch tubing bender operates and what happens tubes
are bent (the tube is a simple two corner that bends 90 degree). Then it shows how thin tube
is harder to form smoothly rather than a thicker metal that can turn way smoother in the
inside. And when it comes to a very thick tube, it is just as smooth as it can be.
The man then gives a trick on how to bend smoother. The trick is heating the metal
that can help aggravated at times. But, the best way that is usually done on very thin wall
metal that must be bent is by filling the tube with dry sand which will support the walls of the
thin metal and distributes the forces given by the tubing bender. So, the conclusion from this
part shows that it is so much easier to bend a thick metal (the thicker the better) rather than
metal with thin wall (the thinner the worse).
The next part of the video then shows hardness of materials. At the beginning, the
man tells that steel for sure is a tough material. But there are 3 kinds of steels you can get,
those are hardened steel, half hard, and soft. The man also mentions about non-ferrous metals
that are alumunium and copper. It then shows a copper that is half-inch that comes in a roll
and its soft. The more we try to bend it by moving it around, the more the molecules are
stressed which leads to more heats created. But it wont stretch no more, and that is not what
we want to get a perfect shape.
Then there is a hand bender plus an alumunium. Turns out it is way too thin, the
aluminium blends but it doesnt collapse like the copper does, but the outside does flattened
because the wall is not thick enough to provide the metal to make a perfect move. So, you
need to do a large radius and do a series of smaller pins to make it blend. The conclusion is
the hand bender is doing just fine for copper and alumunim but not for steel since it is way
too strong. So, for steel you need to use steel half-inch bender that has a rack-and-pinion
drive system. After all, you need a special tool to bend a steel. So, if you ever need a curve on
your car that is tighter than that, you need to cut and sectioning it first.
Next is one-inch bender. As we know there is so much pressure involved in bending
steel. So you can put a hook at the end of the tube which spreads nicely. Jiggle it then engage.

When making one bend, we dont have too worry about any degree or which way it points out,
but, what about more than one? Just put a level on it, pull some pressure to lock it then click a
few times to make it bent then do it all over again. On the left side, you can adjust your
degree as you want.
Now for extremely heavy metal we need a robar tubing. But you just cant bend it
with your hands. Instead, use that red piece of square tubing (shown in the video). It provides
additional leverage for heavy stuff. Next is sheet metal, put a little paper template on some
sheet metal. The sheet metal is half a milimiter thick by the way. The most basic way to
stretch metal is with a hammer or mallet. The man then puts the sheet metal on a sandbag ( he
tries to make a blister panel because it is used a lot in vehicles) to make it bend in the middle,
hit it hard enough untill you get the perfect shape and just reflect the back of the sandbag if it
gets too deep. As we can see he really forces the metal to move into a crown. Then he tries to
flatten the outer sides of the metal using smaller hammer untill its enough. So, the more effort
you take into hitting it, the finer the product.
But, to make bigger ones, there is a machine called english wheel and its for metal
forming that are larger. First, measure it with a sample paper so you can work it in the
machine to create the three dimensional stretch we need just like in the aircraft. However,the
machine only does sheet metal and soft. The man then shows how the machine operates using
a really thin sheet alumunium by putting in the middle part of the machine ( he even said we
can imagine as a hammer) then lock it. Preload it slightly, then move it back and forth
( because there is an egg shaped roller at the bottom) then it will eventually stretch the center
of it. The mtal got to go somewhere so there are streets marks that is where the pressure from
the crowned wheel is forcing it to stretch).
One thing we should watch when working with an english wheel is that there is a lot
of mass in the router, and we can get some momentum going if you get sloppy and allow your
thumb to come over the top roller and be pulled in it and it will hurt you. So, try to keep
your fingers and hands to the side and take your time and just work in the middle. Then you
get your metal stretched already. But, if you need more, you can keep working on it with the
same directions you want it to curve just like the aircraft that is shown in the video. Then if
you want to flatten the outer side, you can use a flat roller just like using a smaller hammer.
So, select the roller depending on the size of the panel. A small pound needs a very high

crown wheel, if you need little curvature, use a wheel that has less curvature. So, just match
the work to what you need. After all, the man says that practice is important.
The main thing with english wheel is to keep it clean, dont use dirty metal that will
cause a damage to the rollers. And dont over crank them, just take your time and do it right. If
you overstretch the middle, its ten times harder to compress it back. The next part is how to
create a professional high quality edge fit. Normally, if you just have one panel and put
another piece of metal on top of it then the air can flow rightly. Dont mix it upside down
because the air can blow the metal away. Then there is a roller jog edge. Put it at the bottom
of a sheet metal then you will get a stepless joint and forms the easiest thing in the world, it
has dark wheels that are made with certain shapes. The machine can move up and down due
to thickness.
By changing the roller, we can even make a beautiful line as we want and also gives it
a structural rigidity it needs to keep from flapping. And there are two rollers that can open
and close so you can set them to different lenghts metals (the machine actually takes two
persons) one person operates, while the other feed the material in.