RAJIVGANDHI COLLEGE OF ENGINEERING AND PUDUCHERRY

TECHNOLOGY

MEE74- METAL FORMING PROCESSES

UNIVERSITY QUESTIONS AND ANSWERS
UNIT-IV
2marks
1. Mention the purpose of providing back relief angle in drawing die. (May 2016)
The back relief angle area of a wire drawing die is designed to strengthen the exit of
the die and prevent breakage of the insert.
2. What do you mean by deep drawing? (May 2016)**

Deep drawing is a process in sheet metal forming by the mechanical action of a punch. A flat
sheet metal blank is formed over a single, rigid, shape defining tool half by a flexible rubber
diaphragm under uniform hydrostatic pressure.

3. Write the features of punching process. (May 2017) **

It is the most cost effective process of making holes in strip or sheet metal for average to high
fabrication. It is able to create multiple shaped holes. Punches and dies are usually fabricated
from conventional tool steel or carbides
4. Define drawing. (May 2017)*
Drawing is a metal working process which uses tensile forces to stretch metal. As the metal
is drawn (pulled), it stretches thinner, into a desired shape and thickness.
Drawing is classified in two types: sheet metal drawing and wire, bar, and tube drawing.
5. Write the process variables in drawing. (May2018)**
The process parameters that affect the success or failure of a deep-drawing operation
includes.
 punch and die radii
 punch to die clearance
 press speed
 lubrication
 type of restraint of metal flow

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6. Discuss different shearing operations performed in sheet metal. (May 2018)

 Shearing
 Punching
 Piercing
 Blanking
 Nibbling
 Lancing
 Slotting
 Bending
 Perforating. Etc.

7. Define drawing ratio. (May 2019)

It is the ratio of the blank diameter to the punch diameter
8. What is blanking? (May 2019 )*
Blanking is a metal fabricating process, during which a metal workpiece is removed from the
primary metal strip or sheet when it is punched. The material that is removed is the new metal
workpiece or blank.
9. Write any two types of blanking die.
 Compound die
 Progressive die
10. Write the advantages of rubber pad forming.
 Extremely suitable for small series thanks to low investment in tools.
 Tooling costs are low, 5 to 10% of deep drawing tooling.
 Single tools, time to market is short.
 High-tech look for a high-tech product.
 Optimum flow through round shapes.
 Not bound to sheet thickness.
 No surface damages.

11. Write the components manufactured by drawing.

Cup, tumbler, wires,rods, tubes, etc..
12. Define wire drawing.

It is a metalworking process used to reduce the cross-section of a wire by pulling the wire
through a single, or series of drawing dies.

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13. Define degree of drawing.

The degree of drawing is measured in terms of “reduction of area” which is defined as the
ratio of the difference cross-sectional area before and after drawing to the initial cross-
sectional area.

14. Write the applications of wire drawing.

There are many applications for wire drawing, including electrical wiring, cables, tension-
loaded structural components, springs, paper clips, spokes for wheels, and stringed musical
instruments.
15. Write the process parameters of sheet forming.
 Tool forces
 Tooling geometry
 Tooling clearances
 Lubrication of tooling surfaces

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11 Marks
1. With neat sketch explain the working of wire drawing.(May 2016) ***

Wire Drawing:
A wire is a circular, small diameter flexible rod. Wire drawing is an cold working process

It is an operation to produce wire of various sizes within certain specific tolerances.

This process involves reducing diameter of thick wire by passing it through a series of wire
drawing dies with successive die having smaller diameter than the preceding one.

Mostly die are made by chilled cast iron, tungsten carbide, diamond or other tool material.
The maximum reduction in area of wire is less than 45% in one pass.

2. Draw and explain the working of stretch forming.(May 2016)***

Stretch forming
Stretch forming is a metal forming process in which a piece of sheet metal is stretched and
bent simultaneously over a die in order to form large contouredparts.

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Stretch forming is performed on a stretch press, in which a piece of sheet metal is securely
gripped along its edges by gripping jaws. The gripping jaws are each attached to a carriage
that is pulled by pneumatic or hydraulic force to stretch thesheet.

The tooling used in this process is a stretch form block, called a form die, which is a solid
contoured piece against which the sheet metal will be pressed. The most common stretch
presses are oriented vertically, in which the form die rests on a press table that can be raised
into the sheet by a hydraulicram.

As the form die is driven into the sheet, which is gripped tightly at its edges, the tensile forces
increase and the sheet plastically deforms into a new shape. Horizontal stretch presses mount
the form die sideways on a stationary press table, while the gripping jaws pull the sheet
horizontally around the form die.

3. Write the advantages of rubber pad forming. (May 2018)

Advantages of rubber pad forming

Unique combination in shape, price

andlead time

Low toolingcosts
Smart and efficient design
byintegratingfunctionalities
Lightweight optimizedconstructions

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More hygiene through design

(noweldingseams)
No sharp edges and little to
nosurfacedamages.
Appealing specific design with
flowingshapes

4. Discuss various operations in sheet metal (Nov 2016) **

Blanking
Blanking is a cutting operation of a flat metal sheet and the article punched out is known as
blank

Blank is the required product of the operation and the metal left behind is considered as a
waste

Punching
It is the cutting operation with the help of which holes of various shapes are produced in the
sheet metal

It is similar to blanking only the main difference is that, the hole is the required product and
the material punched out from the hole is considered as a waste.

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Notching
Similar to blanking however the full surface of punch does not cut the metal

In this operation the metal pieces are cut from the edges of a sheet

Perforating
It is similar to piercing only difference is that holes produced are not in a round shape

In this process, multiple holes which are very small and close together are cut in the sheet
metal.

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Slitting – It is the operation of making an unfinished cut through a limited length only.

Lancing
In this operation, there is a cut of sheet metal through a small length and bending this small
cut portion downwards.

Shaving
This operation is used for cutting unwanted excess material from the periphery of previously
formed workpiece

Very small amount of material is removed in this process.

Shearing
It is a process of cutting a straight line across the strip, sheet or bar. It has three stages

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Plastic deformation, Fracture and Shear

When the metal is placed between upper and lower blades of the shear and the pressure is
applied, plastic deformation of the metal takes place

As the pressure is continued, the fracture crack starts at the cutting edge of the blade.

As the blade descends further, the small fracture meet and the metal is sheared.

Nibbling
This operation is generally substituted by blanking

It is designed for cutting out flat parts from sheet metal

The flat parts ranges from simple and complex contours

It is used only for small quantity of components

Metal forming operations

In metal forming operations, the sheet metal is stressed below the ultimate strength of the
metal

In this operations, no material is removed hence there is no wastage

Metal forming operations include following operations

. Bending, Drawing. Embossing, Forming and Coining

Bending
It is a metal forming operation in which the straight metal sheet is transformed into a curved
form

In bending operations, the sheet metal is subjected to both tensile and compressive stresses

During the operation, plastic deformation of the material takes place beyond its elastic limit
but below its ultimate strength

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Bending methods which are commonly used are

i. U-bending

ii. V-bending

iii. Angle bending

iv. Curling

Drawing
In this operation, punch forces a sheet metal blank to plastically into the clearance between
the punch and die

Finally the blank takes shape of a cup

Embossing
With the help of operation, specific shapes of the figures are produced on the sheet metal

It is used for decorative purposes or giving details like names, trademarks, etc on the sheet
metal

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Forming
In forming operation, sheet metal is stressed beyond its yield point so that it takes a
permanent set and retains the new shape

In this process, the shape of punch and die surface is directly reproduced without any metal
flow

The operation is used in the manufacturing of door panels, steel furniture, air-craft bodies, etc.

Coining (squeezing)
In coining operation, the metal having good plasticity and proper size is placed within the
punch and die and a tremendous pressure is applied on the blank from both ends

Under severe compressive loads, the metal flows in the cold state and fills up the cavity of the
punch and die

The operation is used in the manufacturing of coins, ornamental parts etc.

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Deep drawing
It is a process of making a cup-shaped parts from a flat sheet-metal blank

To provide necessary plasticity for working, the blank is first heated and then placed in
position over the die or cavity

The punch descends and pushes the metal through the die to form a cup, hence this process is
called as cupping

To obtain cup shaped pieces of desired size and wall thickness, the process may be continued
through a series of successively smaller dies and punches.

5. Discuss drawing (wire/rod/tube) operations with suitable sketches. (Nov 2015)**

Wire Drawing:
A wire is a circular, small diameter flexible rod. Wire drawing is an cold working process. It
is an operation to produce wire of various sizes within certain specific tolerances. This

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process involves reducing diameter of thick wire by passing it through a series of wire
drawing dies with successive die having smaller diameter than the preceding one. Mostly die
are made by chilled cast iron, tungsten carbide, diamond or other tool material. The maximum
reduction in area of wire is less than 45% in one pass.

Rod Drawing:
Rod drawing is similar process like wire drawing except it is rigid and has larger diameter
compare to wire. This process needs heavier equipment compare to wire drawing because the
wire can be coiled but a rod should be kept straight. The work piece is first fed into die and
pulled by a carriage which increase its length and decrease its cross section. Now the rod is to
be cut into sections.

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Tube Drawing:
Tube drawing is also similar to other two processes except it uses a mandrel to reduce wall
thickness and cross section diameter of a tube. This mandrel placed with die and the work
piece is pulled by a carriage system as describe in rod drawing. The tube is either circular or
rectangular. It also required more than one pass to complete drawing operation.

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6. Draw and explain the working of stretch forming and rubber pad forming.(***)

Stretch forming
Stretch forming is a metal forming process in which a piece of sheet metal is stretched and
bent simultaneously over a die in order to form large contouredparts.

Stretch forming is performed on a stretch press, in which a piece of sheet metal is securely
gripped along its edges by gripping jaws. The gripping jaws are each attached to a carriage
that is pulled by pneumatic or hydraulic force to stretch thesheet.

The tooling used in this process is a stretch form block, called a form die, which is a solid
contoured piece against which the sheet metal will be pressed. The most common stretch
presses are oriented vertically, in which the form die rests on a press table that can be raised
into the sheet by a hydraulicram.

As the form die is driven into the sheet, which is gripped tightly at its edges, the tensile forces
increase and the sheet plastically deforms into a new shape. Horizontal stretch presses mount
the form die sideways on a stationary press table, while the gripping jaws pull the sheet
horizontally around the form die.

Stretch Forming

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Stretch formed parts are typically large and possess large radius bends. The shapes that can be
produced vary from a simple curved surface to complex non-uniform cross sections. Stretch
forming is capable of shaping parts with very high accuracy and smooth surfaces.

Ductile materials are preferable, the most commonly used being aluminum, steel, and
titanium. Typical stretch formed parts are large curved panels such as door panels in cars or
wing panels on aircraft. Other stretch formed parts can be found in window frames
andenclosures.

Rubber Pad Forming:

Punch less drawing technique using an annular rubber pad. This technique uses a rubber ring
instead of the rigid punch and is used in the production of very deep cups. The limit
of drawing ratio of about 2.2 meant that the production of deep cylindrical cups by
conventional deep drawing with metal tools needed to be done in two or more stages.

As the total drawing ratio increases, the tooling costs also increase since a punch and die are
required for each stage. In rubber pad process radial constraint is applied to the rubber ring
outer cylindrical surface.

With this constraint, due to the incompressibility of the rubber, the volume of the rubber
remains constant and when compressed from the above the only deformation permitted is the
inner diameter which subsequently decreases.

The friction force between the rubber and the sheet metal will force the sheet into the die
cavity. Removal of the compression forces causes the recovery of the rubber ring’s initial
shape. This process is repeated to increase the depth of the cup up to draw ratio of 6. The
process is affected by the friction coefficient, hardness and dimension of the rubber ring.

The fig. shows the rubber pad forming technique where the lank is placed between the die and
the rubber ring. Both components are then placed inside a retainer. A punch is used to press

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the die to the rubber ring and the ensuing friction force will push the sheet metal into the die
cavity.

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1.

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