SDB35103

UNIVERSITI KUALA LUMPUR

MALAYSIAN SPANISH INSTITUTE

COURSE: DESIGN FOR SHEET METAL FORMING

TITLE:
EXERCISE 1

Student’s Name : Muhammad Zulaizad bin Zahrul

ID. Number : 54213119283
Programme : BETA Manufacturing
Semester :5
Lecturer : Mr. Mohd Zaki bin Ab Razak
Submission Date : 17th February 2021

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Question 1
Describe all sheet metal forming processes and identify all characteristics for specific
process. State product example for every process.
There are two types of sheet metal forming processes. The first one is sheet metal forming.
This process transforms the metal sheet into any desired shape. This process can be done by
punch and die of the stamping tool that works on press. The process includes coining,
stamping and ironing. Some changes in thickness are negligible essentially. Examples of
sheet metal forming are sink and large automotive parts, nails nuts and bolts.
The next one is bulk forming or forging. For this process, a billet of material is shaped into the
desired shape by compression. The compressive stress acts in the normal direction to the
surface. Forging is classified into three, which are ‘cold’, ‘warm’ and ‘hot’ forging. Hot
forging can be defined as a metal shaping process in which a malleable metal part worked to
a predetermined shape by one or more processes and heated up to about 75% of its melting
temperature. Warm forging is performed with the workpiece heated to a range that is generally
above the work hardening temperature and below the temperature at which scale forms. Cold
forging is one of the most widely used chipless forming processes, often requiring no
machining other than drilling. The commonly accepted definition is the forming or forging of a
bulk material at room temperature with no heating of the initial slug or inter-stages. The
example of bulk forming are gears, bushed, hydraulic valves and connecting rods.
Question 2
What is metal stamping? Describe type of stamping processes that produce by press machine.
Metal stamping us a process to convert flat metal sheet into specific shapes. Is consists of
complex process and number of forming techniques such as blanking, punching, bending and
piercing. Stamping involves placing sheet metal into the process where during the press, a
tool and die surface form the metal into desired shape. The types of stamping process are:
- Progressive Die Stamping
strip metal is feds through a progressive stamping press. The strip unrolls steadily from
a coil and into the die press, where each station in the tool then performs a different cut,
punch, or bend. The actions of each successive station add onto the work of the previous
stations, resulting in a completed part. It is an ideal solution for metal parts with complex
geometry to meet faster turnaround, lower labour cost, shorter run length and higher
repeatability.

- Short Run Stamping

Short run metal stamping requires minimal upfront tooling expenses and can be an ideal
solution for prototypes or small projects. After the blank is created, manufacturers use a
combination of custom tooling components and die inserts to bend, punch or drill the
part. The custom forming operations and smaller run size can result in a higher per-
piece charge, but the absence of tooling costs can make short run more cost-efficient
for many projects, especially those requiring fast turnaround.

- Deep Draw Stamping

Deep drawing involves pulling a sheet metal blank into the die via a punch, forming it
into a shape. The method is referred to as “deep drawing” when the depth of the drawn
part exceeds its diameter. This type of forming is ideal for creating components that
need several series of diameters and is a cost-effective alternative to turning processes,
which typically require using up rawer materials.

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- Fourslide Stamping
Fourslide, or multi-slide, involves horizontal alignment and four different slides or in other
words, four tools are used simultaneously to shape the workpiece. This process allows
for intricate cuts and complex bends to develop even the most complex parts.