9 DIFFERENT TYPES OF SHEET METAL OPERATIONS WITH DIAGRAMS

Following are the 9 different types of sheet metal operations:

Shearing Operations

Blanking Operations

Punching Operations

Piercing Operations

Trimming Operations

Drawing Operations

Embossing Operations

Bending Operations

Squeezing Operations

1. Shearing

It is a cut in a straight line across a strip, sheet or bar. It leaves a lean edge on the piece of metal is
sheared or cut. In this operation, a sheet metal workpiece is placed or kept between two dies from one
end. And, the punch is hit at the other end of the sheet, producing a shearing effect.

It has 3 basic stages:

 Plastic deformation
 Fracture
 Shear
a) Plastic Deformation

When a metal is placed between the upper and lower blades of the shear and pressure is applied, plastic
deformation takes place. It extends into metal for about 5 to 40% of metal thickness.

b) Fracture

At the point of greatest stress concentration fracture takes place.

c) Shear

Small fractures are found and the metal is sheared.

2. Blanking

It is an operation of cutting a whole piece from sheet metal. In which enough scrap is left all around as
shown in fig. A punch and die is applied for this type of sheet metal operation.

3. Punching
It is an operation of producing circular holes on a sheet of metal by a punch and die. This is the exact
opposite of blanking but the operation is nearly the same. A Punch and die are further used here such as
blanking operations.

4. Piercing

Piercing is the process in which desired shape holes are produced in a piece of sheet metal without
eliminating any material from the sheet or removing a very small amount of material as shown in the
figure. Both punch and die are also applied in this operation. The punch used in the piercing operation is
usually bullet-shaped.

5. Trimming

The trimming operation is also known as shaving operation. It is a finishing operation by removing the
burrs from the cut edges is taken out in order to make edges smooth and also provide dimensional
accuracy.

6. Drawing

It is an operation of producing thin-walled hallows or vessel shaped parts from sheet metal. It can be
divided into two categories:
1. Deep drawing

2. Shallow drawing

a) Deep Drawing

The length of depth of the object to be drawn is deeper than its width.

b) Shallow Drawing

The length of the object to be drawn is less than its width. The examples of drawing are pans, tubes and
cams.

7. Embossing

It is the metalworking operation which is used to create raised surfaces or lettering in sheet metal. There
is no change in metal thickness during this operation.
8. Bending

It occurs when forces are applied to localized areas. Here the metal flow is uniform along the bend axis
with the inner surface in compression and outer surface in tension.
Types of bending

Edge bending

V-bending

U-bending

Offset bending

Channel bending

1. Edge Bending

It is a type of bending operation, In which a piece of sheet metal is fixed or held between two
dies from one end, as shown in the fig. Then the other end is forced to strike upon the punch
which is free or unfixed. Thus, the free or unfixed edge of the sheet metal piece is bent to make
the forming process.
2. V-bending
In this type of bending operation, when a piece of sheet metal is pressed between the die and
the punch; It is formed into a V-shape in the die.
3. U-bending

In this type of a bending operation, in which when the punch is pressed by a force to move into the
die, the sheet metal piece gets formed into a U-shape.

4. Offset Bending

It is a type of bending operation, in which a piece of sheet metal is formed into an offset shape with
the help of a punch and die.
5. Channel Bending

In this type of a bending operation, in which when a force is used to the punch to move into the die,
the sheet metal piece, in between the punch and die, gets the shape according to the shape of the
die and punch i.e. a channel shape.

9. Squeezing

It is a quick and widely used way of forming ductile metals. It has different operations such as sizing,
coining, riveting etc.

1. Sizing

Sizing operation is a squeezing operation that reduces the thickness of the metal. The sizing is done
in an open die and only the surface where the die and workpiece touch will be sized.
2. Coining

It is a process of pressing metal in a die so that it flows into the die space. For example , Medals,
Coins, and jewelry.

The sheet metal operation depending on the type of stress-induced:

SI.No. Stress Induced Operations

1. Shear Shearing, Blanking, Piercing and

Trimming

2. Tension Stretch forming

3. Compression Coining and Sizing etc

4. Tension and Drawing, Bending, Forming etc

Compression

Electrolytic process

An electrolytic process is the use of electrolysis industrially to refine metals or compounds at a high
purity and low cost. Some examples are the Hall-Héroult process used for aluminium, or the
production of hydrogen from water. Electrolysis is usually done in bulk using hundreds of sheets of
metal connected to an electric power source. In the production of copper, these pure sheets of
 copper are used as starter material for the cathodes, and are then lowered into a solution such as
copper sulphate with the large anodes that are cast from impure (97% pure) copper. The copper
from the anodes are electroplated on to the cathodes, while any impurities settle to the bottom of
the tank. This forms cathodes of 99.999% pure copper.

Alternative

An electrolyte is such a chemical that's atoms are normally closely bonded together but when it is
dissolved in water, its molecules split up into positive and negative ions move freely in the solution.. The
positively charged ions are referred as cations whereas negatively charged ions are referred as anions.
Both cations and anion Principle of Electrolysis

As discussed in the definition of electrolyte, whenever any electrolyte gets dissolved in water, its
molecules split into cations and anions moving freely in the electrolytic solution. Now two metal rods
are immersed in the solution and an electrical potential difference applied between the rods externally
preferably by a battery. These partly immersed rods are technically referred as electrodes. The electrode
connected with negative terminal of the battery is known as cathode and the electrode connected with
positive terminal of the battery is known as anode. The freely moving positively charged cations are
attracted by cathode and negatively charged anions are attracted by anode. In cathode, the positive
cations take electrons from negative cathode and in anode, negative anions give electrons to the
positive anode.

For continually taking and giving electrons in cathode and anode respectively, there must be flow of
electrons in the external circuit of the electrolytic. That means, electric current continues to circulate
around the closed loop created by battery, electrolytic and electrodes. This is the most basic principle of
electrolysis.

#2 EDM

Working of EDM machine

EDM drills bore holes with a long brass or copper tube electrode that rotates in a chuck with a
constant flow of distilled or deionized water flowing through the electrode as a flushing agent and
dielectric. The electrode tubes operate like the wire in wire-cut EDM machines, having a spark gap
and wear rate.

Working principle: The principle of working of EDM is based on the erosion of the material by
repetitive sparks between the workpiece and the tool submerged in a bath of the dielectric medium.
The working system is illustrated in Fig. 2.1. The workpiece and tools are two electrodes connected
by D.C pulse generator.

Electric discharge machining can be divided into three common types, Die sinking EDM, Wire EDM
and hole drilling EDM.

Electrical discharge machining (EDM) is a non-traditional machining process based on removing

material from a part by means of a series of repeated electrical discharges between tools, called
electrodes, and the part being machined in the presence of a dielectric fluid.

Electrical discharge machining (EDM) is a non-traditional form of precision machining that uses
thermal energy instead of mechanical force to remove material from a workpiece. It is sometimes
referred to as Spark Machining since it utilizes electrical sparks that are near 8000º C to 12000º C.

What is Electrical Discharge Machining (EDM) Process and How it Works?

Electrical Discharge Machining (EDM) is a non traditional machining and electro thermal process in
which material from the workpiece is removed by using electrical discharges (sparks).

It was first observed in 1770 by Joseph Priestley. He was an English physicist.

In EDM machine the material is removed by rapidly recurring (repeating) discharges of current in
between the electrodes. The electrodes are separated by dielectric liquid and a high voltage is
applied across it.

It is used to machine those materials which are difficult to machine and have high strength
temperature resistance.

EDM can be used to machine only electrically conductive materials. Otherwise it cannot be used.

One of the electrodes is called as tool and other is called as workpiece. Here the tool is connected
with the negative terminal of the power supply and the workpiece is connected with the positive
terminal.

WORKING PRINCIPLE
In Electrical discharge machining; a potential difference is applied across the tool and w/p in pulse
form. The tool and workpiece must be electrically conductive and a small gap is maintained in
between them. The tool and workpiece is immersed in a dielectric medium (kerosene or deionized
water).

As the potential difference is applied, electrons from the tool start to move towards the workpiece.
Here the tool is negative and w/p is positive. The electrons moving from the tool to the w/p collide
with the molecules of dielectric medium.

Due to the collision of electrons with the molecule, it gets converted into ions. This increases the
concentration of electrons and ions in the gap between the tool and w/p. The electron moves
towards the w/p and ions towards the tool.

An electric current is set up in between the tool and w/p and called as plasma. As the electrons and
ions strikes the w/p and tool, its kinetic energy changes to heat energy. The temperature of the heat
produced is about 10000 degree Celsius. This heat vaporizes and melts the material from the
workpiece. As voltage is break down, the current stops to flow between the tool and w/p. And the
molten material in the w/p is flushed by circulating dielectric medium leaving behind a crater.

The spark generation is not continuous because constant voltage is not applied across the
electrodes. The voltage is applied in pulse form.

Types of Electrical Discharge Machine

There are two types of EDM machine

(i) Ram/Sinker EDM : This EDM machine consists of tool and workpiece immersed in a dielectric
medium. It consists of ram type tool and it may be created according to the shape or form required
to produce on the workpiece. It is also called as cavity type or volume EDM.

(ii) Wire EDM: In wire EDM, thin single-strand wire is used to cut the material from the workpiece.
The wire is usually made of brass. A constant gap is always maintain between the wire and w/p. The
wire is continuously fed through the workpiece submerged in a tank with dielectric medium. Here
spark is generated in the gap between the wire and workpiece. It is used to cut metal as thick as 300
mm and to make punches, dies, and tools from hard metals that are difficult to cut from other
methods.

Equipment

The various equipment used in Electrical Discharge Machining are

1. Dielectric Reservoir, Pump and Circulating system

Pump is used to circulate the dielectric medium between the two electrodes ( tool and workpiece).
Kerosene or deionized water is used as dielectric medium.

2. Power Generator and Control Unit

Generator is used to apply potential difference. The voltage used in this machining process is not
constant but it is applied in pulse form. A control unit is used to control the different operation
during machining process.

3. Working Tank with Work Holding Devices

It has working tank with a work holding device. The workpiece is hold in the work holding devices.
The tank contains dielectric medium.

4. Tool Holder

It is used to hold the tool.

5. Servo System to Move the Tool

A servo system is used to control the tool. It maintains the necessary gap between the electrodes
( tool and workpiece).
Working of Electrical Discharge Machining (EDM)

In EDM, first the tool and w/p is clamped to the machine. After that with the help of a servo
mechanism a small gap (of human hair) is maintain in between the tool and workpiece.

The tool and workpiece is immersed in dielectric medium (kerosene of deionised water).

A potential difference is applied across the Electrode. An electric spark is generated in between the
tool and workpiece. This spark generates a heat of about 10000 degree Celsius. And due to this heat
the material from the workpiece starts to vaporize and melts.

The spark generation in electrical discharge machining is not continuous. As the voltage breaks, the
dielectric fluid flushes away the molten materials leaving behind a crater.

This process keep continue and machined the workpiece.

Advantages

It can be used to machine any material that is electrically conductive.

It can easily machine thin fragile sections such as webs or fins without deforming the part.

Complex dies sections and molds are produced accurately, faster and at lower price.

It is burr-free process.

It does not involve contact between the tool and workpiece. So delicate sections and work material
can be machined easily without any distortion.

It can machined complex shapes which is not manufactured by the conventional machine tools.

It can produce tapered holes.

Disadvantages

It can machine only electrically conductive materials.

Low rate of metal removal.

More tool wear during machining.

Takes extra cost and time for the preparing electrodes for ram/sinker EDM.

High power consumption.

Overcut is formed in EDM.

Application
It is mostly used by mold making and dies industries.

It is used in prototype manufacturing in aerospace, automobile and electronic industries.

It is used for coinage die making.

It is used to create small holes in variety of application.

It is used to disintegrate parts which cannot be disintegrate easily such as broken tools (studs, bolts
drill bit and taps) form the workpiece.