MIEG 6421 - Sheetmetal Forming Processes

FORMING & ADVANCED JOINING PROCESSES
(MIEG 6421)
Getasew Ashagrie (Ph.D.)

School of Mechanical and Industrial Engineering
Office: 348
E-mail: getasew.taddese@aau.edu.et
January 2024
AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING AAU / AAiT
Sheet metal forming processes
AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2

Contents
Module 3 Sheet metal forming processes
 Introduction
 Sheet metal cutting operations
 Engineering analysis of sheet metal cutting
 Other cutting operations
 Bending operations in Sheet metal work
 Engineering analysis of bending
 Other bending and forming operations
 Drawing operations
 Engineering analysis of drawing
 Other drawing operations
 Defects in drawing
 Operations performed with metal tooling
 Die and presses for sheet metal processes
 Sheet metal operations not performed on presses

Introduction
About sheet metal
 Sheet metal working

(forming) includes cutting
and forming operations on
relatively thin sheets of
metal.
 Typical sheet metal

thickness: 0.4 to 6 mm.
 Thickness > 6 mm – sheet

metal is referred to as a
plate.
 Most commonly used sheet

metal is low carbon steel
0.06% to 0.15% C steel.

Introduction
Sheet metal forming
 Sheet metal is simply metal formed into thin and

flat pieces.
 It is one of the fundamental forms used in

metalworking, and can be cut and bent into a
variety of different shapes.
 Thicknesses can vary significantly, although

extremely thin thicknesses are considered foil or
leaf, and pieces thicker than 6 mm are considered
plate.
 The raw material for sheet metal manufacturing

processes is the output of the rolling process.
 Typically, sheets of metal are sold as flat,

rectangular sheets of standard size.
 The most common sheet metal working processes

(operations) are cutting, bending, and drawing.
Introduction
Characteristics of sheet metal parts
 High strength
 Good dimensional accuracy
 Good surface finish
 Relatively low cost
 Economical mass production for
large quantities
Commercial importance of sheet

metal forming
 Automobile and truck bodies,

 Airplane,
 Railway cars and locomotives,
 Farm and construction equipment,
 Small and large appliances,
 Office furniture and equipment, etc.

Introduction
Sheet metal working – Terminology
 Press tools - Machine tools where most of

the sheet metal operations are
performed.
 Stamping press - A term used to

distinguish presses used in sheet metal
forming from forging and extrusion
presses.
 Punch and die or stamping die – The

tooling that performs sheet metal work.
These operations could be cutting,
bending, and drawing.
 Stampings - sheet metal products.
 Strips and coils – Sheet metal is often

presented to the press as long strips and
coils.

Cutting operations
Three press working processes
 The three press working processes that cut

metals by the shearing mechanism.
 Can be described as shearing, blanking

and punching.
 Shearing
 Cutting operation along a straight line

between two cutting edges.
 Performed on machines called power

shears or squaring shears.
 The upper blade of the power shears is

often inclined to reduce the required
cutting force.

Cutting operations
Three press working processes
 Blanking
 Cutting of metal along a closed outline

in a single step to separate the piece
from the surrounding stock.
 Blank is the part that is cut out, which

is the desired product.
 Punching
 Similar to blanking except that it

produces a hole, and the separated
piece is a scrap and it is called slug.
 The desired part is the remaining

stock.

Cutting operations
Shearing actions
 Sheet metal cutting is accomplished by a shearing action between two sharp

cutting edges.
Figure shows the shearing action
1. Just before punch contacts the work

2. Punch begins to push into work causing plastic deformation
3. Punch compresses and penetrates into work causing a smooth cut surface.
4. Fracture is initiated at the opposing cutting edges that separate the sheet.

Cutting operations
Shearing actions
 Sheet metal cutting is accomplished by a shearing action between two sharp

cutting edges.
 The shearing action is depicted in the four stop-sketch actions.
 The upper cutting edge (the punch) sweeps down past the a stationary lower
cutting edge (the die).
 As the punch begins to push into the work;
 Plastic deformation occurs in the surface of the sheet, then

 Penetration (in a zone about one-third of the thickness of the sheet) occurs –
punch compresses the sheet and cuts into the metal.
 Fracture is initiated as the punch continues to travel into the work.
 A correct clearance between the punch and die, the two fracture lines meet,
and results a clean separation of the work into two pieces.

Cutting operations
Shearing actions
 Characteristics of sheared
edges of the work.
 Four regions: rollover,

burnish, fractured zone, and
burr.
 Rollover - Located at the top of the cut surface. It is the depression made by the punch
in the work prior to cutting. It is where the initial plastic deformation occurred in the
work.
 Burnish – It is a relatively smooth region located just below the rollover. It results from
penetration of the punch into the work before fracture began.
 Fracture zone – A relatively rough surface of the cut edge located below the burnish
formed by continued downward movement of the punch.
 Burr – A sharp corner at the bottom edge caused by elongation of the metal during final
separation of the two pieces.

Cutting operations
Shearing
 Shearing is a process for cutting sheet metal to size out of a larger stock such
as roll stock.
 Shears are used as the preliminary step in preparing stock for stamping
processes, or smaller blanks for CNC presses.
 The shearing process produces a shear edge burr, which can be minimized to
less than 10% of the material thickness.
 The burr is a function of clearance between the punch and the die, and the
sharpness of the punch and the die.
TIP:
How can we minimize a Burr? Can we avoid it? Provide

your explanation based on the various parameters in sheet
metal operations.

Cutting operations
Engineering analysis of sheet metal cutting
 Process parameters in sheet metal cutting are:

Clearance between punch and die, stock thickness,
metal type and its strength, and length of cut.
 Clearance (c)
 Distance between punch and die
 Typical values: 4% to 8% of the sheet metal

thickness (t).
 The correct clearance depends on type of sheet

metal and thickness and the recommended
clearance is calculated by:
C  Act

Cutting operations
Engineering analysis ...
 Clearance (c)
 The effect of improper clearance (too small or

too large).
 Too small c - The fracture lines tend to

pass each other, causing a double
burnishing (plastic deformation) and
larger cutting forces. (Figure 1)
 Too large c - The metal becomes pinched

between the cutting edges and an
excessive burr results. (Figure 2)
 In special operations requiring very straight

edges (such as shaving and fine blanking),
clearance is only about 1% of stock
thickness.
Cutting operations
 Clearance (c)
 Clearance allowance (Ac) is determined according to type of metal. The

value of Ac is given for three sheet metal groups, grouped into three for
convenience.
Metal group Ac
1100S & 5052S aluminum alloys, all tempers 0.045
2024ST & 6061ST aluminum alloys; brass, all tempers; 0.060
soft cold-rolled steel, soft stainless steel
Cold-rolled steel, half hard; stainless steel, half-hard and 0.075
full-hard
 These clearance can be applied to conventional blanking and hole

punching operations to determine proper size of punch and die.
 The die opening must be larger than the punch size.

Cutting operations
 Clearance (c)
 To add the clearance value (to the

die) or subtract (from the punch
size) depends on whether the part
being cut out is a blank or a slug.
See Figure for a circular part.
 The outer dimension of the part cut

out of the sheet will be larger than
the sheared edge due to the
geometry of the sheared edge.
 Thus, punch and die sizes for a round blank of diameter Db are;
 Blanking punch diameter = Db – 2c

 Blanking die diameter = Db
Cutting operations
 Clearance (c)
 Punch and die sizes for a round hole of

diameter Dh are;
 Hole punch diameter = Dh

 Hole die diameter = Dh + 2c
 In order for the slug or blank to drop through

the die, the die opening must have an angular
clearance of 0.250 to 1.50 on each side.
Angular clearance
Cutting operations
 Cutting Forces (F)
 Estimation of cutting forces is used in deciding the size (tonnages) of the presses
needed.
 The cutting force (F) in sheet metal working is determined by
F  StL or F  0.7 TS  tL

Where
 S = Shear strength of the sheet metal, MPa
 t = Stock thickness, mm.
 L = Length of the cut edge, mm.
 TS = Ultimate tensile strength, MPa
 In blanking, punching, slotting, and similar operations, L is the perimeter length of the
blank or hole being cut. The minor effect of clearance in determining L can be
neglected.
 The Second formula with TS can be used if the shear strength of the sheet metal is
unknown.
Exercise
A round disk of 150mm diameter is to be blanked from a strip of 3.2mm,

half-hard cold rolled whose shear strength = 310 MPa. Determine
a) The appropriate punch and die diameters, and

b) Blanking force
 The clearance allowance for metal group of half-hard cold rolled steel is AC= 0.075.
 Clearance, C = ACt = 0.075 ×3.2mm = 0.24mm
 Die size
 Die opening diameter = diameter of blank = Db = 150 mm

 Punch diameter = Db – 2C = 150 mm – 2 ×0.24 mm = 149.52mm
 Blanking force
 It is assumed that the entire perimeter of the part is blanked at one time. Thus, the length of the
cut edge is
L   Db  150  471.2mm
 F = StL
= 310 MPa × 3.2 × 471.2 = 467.5 N

Cutting operations
Other cutting operations
 Cutoff
 A shearing operation in which blanks are

separated from a sheet-metal strip by
cutting the opposite sides of the part in
sequence. A new part is produced with
each cut.
 Features of a cutoff operation that

distinguish it from conventional shearing
operations
 The cut edges are not necessarily

straight
 The blanks can be nested (layout

multiple parts on a single sheet) on the
strip in such a way that scrap is
AAU / AAiT avoided. SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 21
Cutting operations
 Parting
 Cutting a sheet metal strip by a punch with

two cutting edges that match the opposite
sides of the blank.
 The part outline has an irregular shape that

precludes perfect nesting of the blanks on
the strip.
 It is less efficient than cutoff since it results

in some scraps.

Cutting operations
 Slotting
 A punching operation that cuts out an elongated or

rectangular hole.
 Perforating
 Punching of a pattern of holes in sheet metal. The

hole pattern is usually for decorative purposes, or
to allow passage of light, gas, or fluid.
 Notching and Seminotching
 Notching involves cutting out a portion of metal

from the side of the sheet or strip.
 Seminotching removes a portion of metal from the

interior sheet. The metal removed by semi
notching creates part of the blank outline, while
punching and slotting create holes in the blank.
Cutting operations
 Trimming
 A cutting operation performed on a formed part to

remove excess metal and establish size.
 An example can be trimming the upper portion of a deep

drawn cup to leave the desired dimensions on the cup.
 Shaving
 A shearing operation performed with very small

clearance to obtain accurate dimensions and cut edges
that are smooth and straight.
 It is typically performed as a secondary or finishing

operation on parts that have been previously cut.

Cutting operations
 Fine blanking
 A shearing operation used to blank sheet metal

parts with close tolerances and smooth, straight
edges in one step.
 Start of the cycle – A pressure pad with a V-

shaped projection applies a holding force Fh
against the work adjacent to the punch in order
to compress the metal and prevent distortion.
 Then – the punch descends with a slower than Fine blanking

normal velocity and smaller clearances to
provide the desired dimensions and cut edges.
 The process is reserved for relatively small

stock thickness and targets 100% smooth cut
rather than common blanking (stamping).

Bending operations
 Bending operation in sheet metal work.
 Straining of the metal around a straight axis.
 During the bending operation, the metal on

the inside of the neutral plane is
compressed, while the metal on the outside
of the neutral plane is stretched. a) Bending in sheet metal
 Metal is plastically deformed so that the

bend takes a permanent set upon removal
of the stresses that caused it.
 Bending produces little or no change in the

thickness of the sheet metal.
 Bending operations are performed using

punch and die tooling. b) Both compressed and
tensile elongation of the
metal occur in bending

Bending operations
 Types of bending operations
 V-bending
 Performed with a V-die.
 Sheet metal is bent between a

V-shaped punch and die.
 Included angle ranging from

very obtuse to very acute.
V – bending
 It is generally used for low-
production operations. 1. Before bending
2. After bending
 Use relatively simple &
inexpensive dies.

Bending operations
 Edge bending (1 of 2)
 Performed with a wiping

die.
 Involves cantilever loading

of the sheet metal.
 A pressure pad is used to

apply a force Fh to hold the Edge bending
base of the part against
1. Before bending
the die.
2. After bending
 The punch forces the part
to yield and bend over the
edge of the die.

Bending operations
 Edge bending (2 of 2)
 Edge bending is limited

to bends of 900 or less.
 More complicated wiping

dies can be designed for
bend angles greater than
900.
Edge bending
 Generally used for high
1. Before bending
production work since the
2. After bending
pressure pad, wiping dies
are more complicated
and costly than V-dies.

Bending operations
Engineering analysis of bending
 The metal of thickness, t, is bent

through an angle called the bend angle
α.
 The bend radius R is normally

specified on the inside of the part than
at the neutral axis. . Bending of sheet metal
 R is determined by the radius on the

tooling used to perform the operation.
 The bend is made over the width of the

workpiece w.
Both compression and tensile

elongation of the metal occur in
bending

Bending operations
 Bending allowance (Ab)
 If bend radius is small relative to stock thickness,

the metal tends to stretch during bending.
 It is necessary to determine the length of the Bending of sheet metal

neutral axis before bending to account for
stretching of the final bent section.
 The bending allowance is estimated as;


Ab  2  R  Kbat 
360
Where:
• Ab – bending allowance, mm Both compression and tensile
• α – bend angle, degrees elongation of the metal occur in
• R – bend radius, mm bending
• t – stock thickness, mm
• Kba – a factor to estimate stretching

 Bending allowance (Ab)
 Recommended design values for Kba.
 If R < 2t, Kba = 0.33

 If R ≥ 2t, Kba = 0.50 Bending of sheet metal
 The values of Kba predict that stretching occurs

only if bend radius is small relative to sheet
thickness.
Both compression and tensile

elongation of the metal occur in
bending

Bending operations
 Spring back (SB)
 Is a decrease in bend angle and an increase in bend radius.
 During the operation, the work is forced to take the radius, Rt, and included angle α’b
which is determined by the bending tool (punch in V-bending).
 After the punch is removed, the work springs back to radius R and included angle α’.
Spring back in bending
During the operation After the punch is removed

Bending operations
 When the bending pressure is removed at the end of the deformation

operation, elastic energy remains in the bent part, causing it to recover
partially towards its original shape.
 This elastic recovery is called spring back which is the increase in included
angle of the bent part relative to the included angle of the forming tool after it
is removed.
 '   b' '

SB   b'
 b'
 The amount of SB increases with modulus of elasticity and yield strength of
the work metal.

Bending operations
 Two compensation methods for spring back: Over bending and Bottoming
 Over bending
 The punch angle and radius are fabricated slightly smaller than the specified
angle on the final part so that the sheet metal springs back to the desired
value.
 Bottoming
 Involves in squeezing the part at the end of the stroke, thus plastically
deforming it in the bend region.

Bending operations
 Bending force
 The force required to perform bending

depends on the geometry of the
punch-and-die and the strength,
thickness, and length of the sheet
metal. (a) V die (b) Wiping die
 The maximum bending force can be Die opening dimension, D

estimated as
K bf TS  wt 2
F
D
Where
• F – bending force, N
• TS – tensile strength of the sheet metal, MPa
• w – width of part in the direction of the bend axis, mm.
• t – stock thickness, mm
• D – die opening dimension, see Fig.
• Kbf – constant that accounts for differences encountered in an actual bending process. It
depends on the type of bending : V bending (Kbf = 1.33 ) and Edge bending (Kbf = 0.33)

Exercise
A sheet metal blank is to be bent as shown. The metal has a

modulus of elasticity = 205MPa, yield strength = 275MPa, and
tensile strength = 450MPa. Determine
a) The starting blank size
b) The bending force if a V-die is used with a die opening

dimension = 25mm.
Ans.
a) Ab = 6.08, then length of the blank = 38+6.08+25 = 69.08mm
b) F = 10,909N

Bending operations
Other bending and forming operations
 ‘Other’ operations consider bending

operations where bending occurs over a
Flanging
curved axis rather than a straight axis or
other features that differentiate them from (a) Straight flanging
those operations previously described.
 Flanging
 A bending operation in which the edge

of the sheet metal part is bent at a 900 (b) Stretch flanging
angle (usually) to form a rim or flange.
 The flange can be formed over a

straight bend axis (a), or that it can
involve some stretching or shrinking of (c) Shrink flanging
metal (b and c).

Bending operations
 Hemming
(a) Hemming
 Bending the edge of the sheet over
itself, in more than one bending step.
It is often done to eliminate the sharp
edge of the piece, to increase
stiffness, and to improve appearance.
 Seaming (b) Seaming
 Two sheet metal edges are

assembled.
 Curling (or Beading)
 Forms the edges of the part into a roll (c) Curling

or curl. It is done for purpose of
safety, strength, and aesthetics.
 Examples: Hinges, pots and pans,

pocket-watch cases.
Bending operations
 Miscellaneous bending operations
(a) Channel bending

(b) U bending
(c) Air bending
(d) Offset bending
(e) Corrugating
(f) Tube forming

Drawing operations
 Drawing is an operation to make cup-

shaped, box-shaped, or other complex-
curved and concave parts. It is done by
placing a piece of sheet metal over a
die cavity and then pushing the metal
into the opening with a punch.
 The blank must be held down flat

against the die by a blank holder.
 Common parts: Beverage cans,

ammunition shells, sinks, cooking pots,
and automobile body panels.
• c – Clearance
• Db – Blank diameter
• Dp – Punch diameter
• Rd – Die corner radius
• Rp – Punch corner radius
• F – Drawing force a) Drawing of a cup-shaped part
• Fh – Holding force (1) Start of operation before punch contacts work,
(2) Near end of stock
b) Corresponding work part: (1) Straight blank, (2) Drawn part

Drawing operations
Mechanics of drawing
 A blank diameter, Db, is drawn into a

die cavity by means of a punch with
diameter, Dp.
 The punch must have a corner radii,

given by Rp and Rd. For sharp corner,
Rp = Rd = 0.
 The sides of the punch and die are

separated by a clearance, c. This
clearance in drawing is about 10%
greater than the stock thickness:
c = 1.1t
 A downward force, F, is applied by the

punch and a downward holding force Fh
is applied by the blank holder.

Drawing operations
 Stages in deformation of the work in

deep drawing.
1. Punch makes initial contact with

the work.
2. Bending
3. Straightening
4. Friction and compression
5. Final cup shape showing effects
of thinning in the cup walls.

Drawing operations
 Role of friction and

compression
 Friction and compression play

important roles in the flange of
the blank.
 In order for the material in the

flange to move toward the die
opening, friction between the  Compression, besides friction, occurs
sheet metal and the surfaces of in the outer edge of the blank. As the
the blank holder and the die after blank is drawn toward the center, the
metal flow begins, dynamics outer diameter becomes smaller. Since
friction governs the process. volume is maintained, the metal is
squeezed and becomes thicker as the
 Magnitude of the holding force perimeter is reduced. This often results
applied by the blank holder, as in wrinkling of the remaining flange of
well as the friction conditions at the blank, especially when thin sheet
the two interfaces, are metal is drawn, or when the blank
determining factors in the holder force is too low. It is a condition
success of this aspect of the which can’t be corrected once it has
drawing operation. occurred.

Drawing operations
 Holding force
 Applied by the blank

holder is a critical
factor in deep drawing.
 Too small holding force

result in wrinkling.
 Too large holding force  The force applied by the punch is opposed by the
prevents the metal metal in the form of deformation and friction in the
from flowing properly operation.
toward the die cavity,
resulting in stretching  A portion of the deformation involves stretching and
and possible tearing of thinning of the metal as it is pulled over the edge of
the sheet metal. the die opening.
 Up to 25% thinning of the side wall may occur in a

successful drawing operation, mostly near the base
of the cup.
Drawing operations
Engineering analysis of drawing
 Measures of drawing (three measures)
1. Drawing ratio (DR)
 One of the measures of the severity of a deep

drawing operation. It is most easily defined for a
cylindrical shape as the ratio of blank diameter (Db)
to the punch diameter (Dp). Db
DR 
 The greater this ratio, the more sever the operation. Dp
 An approximate upper limit is a value of 2.0.
 The actual limiting value for a given operation

depends on punch and die corner radii (Rp and Rd),
friction conditions, depth of draw, and characteristics
of the sheet metal (e.g., ductility, degree of
directionality of strength properties in the metal).

Drawing operations
Engineering analysis of drawing
 Measures of drawing (three measures)
2. Reduction (r)
 It is another way to characterize a drawing operation. Db  D p

Since DR≤ 2.0, the value of reduction ratio, r, should r
be less than 0.50. Db
3. Thickness-to-diameter ratio (t/Db)
 It is the third measure of deep drawing. It is

determined as thickness of the starting blank (t)
divided by the blank diameter (Db).
 It is often expressed as a percentage.
 It is desirable for the t/Db ratio to be greater than 1%.
 As t/Db decreases, tendency for wrinkling increases.

Exercise
A drawing operation is used to form a cylindrical cup with inside

diameter = 75mm and height = 50mm. The starting blank size =
138mm and the stock thickness = 2.4mm. Based on these data, is
the operation feasible? Furthermore, determine
a) Drawing force
b) Holding force, given that the tensile strength of the sheet
metal (low-carbon steel) = 300MPa and yield strength =
175 MPa. The die corner radius = 6mm.
Feasibility is assessed by determining the drawing ratio, reduction ratio, and thickness-to-
diameter ratio: DR = 1.84, r = 45.65%, and t/Db = 1.7%. The drawing operation is feasible
because DR<2.0, r < 50%, t/Db >1%.
a) F = 193,396N
b) Fh = 86,824 N

Drawing operations
Other drawing operations
 Redrawing
 More than one drawing step is required if

the shape change required by the part
design is too sever or too high drawing
ratio.
 Redrawing is the second or any further

drawing step.
Redrawing of cup
 General guide for redrawing
1. Start of redraw
 The maximum reduction of the 2. End of stroke
starting blank should be 40% - 45%.
• v – punch velocity
 For the second draw (first redraw), • F – applied punch force
the maximum reduction should be • Fh – blank holder force
16%.

Drawing operations
 Reverse drawing
 It is a related operation to redrawing

where a drawn part is positioned face
down on the die that the second
drawing operation produces a
configuration as shown.
 In this process, the deformation is

easier (less strain hardening and Reverse drawing
requires low force) since the sheet
metal is bent in the same direction at 1. Start of redraw
the outside and inside corners of the 2. Compression
dire in reverse drawing, while in
redrawing the metal is bent in the • v – punch velocity
opposite direction at the two corners. • F – applied punch force
• Fh – blank holder force

Drawing operations
 Drawing without blank holder
 The primary functions of blank holder is

to prevent wrinkling of the flange while
the cup is being drawn.
 When the thickness-to-diameter ratio of

the blank increases, the tendency of
wrinkling is reduced.
Drawing without blank holder
 If t/Db ratio is large enough, drawing can
be accomplished without a blank holder. 1. Start of the process
2. End of process
 Limiting conditions for drawing without a
blank holder can be estimated from; • v – motion
• F – applied force
Db – DP <5t

v – motion
Other drawing operations F – applied
force
 Drawing without blank holder
 The die must have the shape of a funnel

or cone to permit the material to be
properly drawn into the die cavity.
 If deformation is feasible without blank

holder, it has advantages of lower cost
tooling and a simpler press, because the
need to separately control the Drawing without blank holder
movement of the blank holder and
punch can be avoided. 1. Start of the process
2. End of process

Drawing operations
Defects in drawing
1. Wrinkling in the flange
 A series of ridges that form radially in the

undrawn flange of the work part due to
compressive buckling.
1
2. Wrinkling in the wall
 If and when the wrinkled flange is drawn into the

cup, these ridges appear in the vertical wall.
2
3. Tearing
 It is an open crack in the vertical wall, usually

near the base of the drawn cup, due to high
tensile stresses that cause thinning and failure of
the metal at this location. It also occur as the
metal is pulled over a sharp die corner. 3

Drawing operations
Defects in drawing
4. Earing
 The formation of irregularities (called ears) in the

upper edge of a deep drawn cup, caused by the
anisotropy in the sheet metal. If the material is
perfectly isotropic, ears don’t form.
4
5. Surface scratches
 Can occur on the drawn part if the punch and die

are not smooth or if lubrication is insufficient.

Drawing operations
Operations performed with metal tooling
 Ironing
 In deep drawing, flange is compressed by the

squeezing action of the blank perimeter seeking a 1
smaller circumference as it is drawn toward the die
opening.
 Due to this compression, the sheet metal near the

outer edge of the blank becomes thicker as it
moves inward.
2
 If the thickness of this stock is greater than the
clearance between the punch and die, it will be
squeezed to the size of the clearance, a process
known as ironing.
Ironing to achieve a more
uniform wall thickness in a drawn
 Note the thinning and elongation of walls in the cup
Figure. 1) Start of process
2) During process

Drawing operations
 Coining
 It is a special application of closed die forging

in which fine details in the die are impressed
into the top and bottom surfaces of the work
part where there is a little flow of metal in 1 2
coining
 Coining is used to form indentations and

raised sections in the part. The indentations
result in thinning of the sheet metal, and the
raised sections result in thickening of the
metal.
3
 Common application is minting of coins. It is
also used to provide good surface finish and Coining
dimensional accuracy on work parts made by a) Start of cycle
other operations. b) Compression stroke
c) Ejection of finished part

Drawing operations
 Embossing
 Embossing is a forming operation used to

create indentations in the sheet such as raised
lettering or strengthening ribs.
 In Embossing, the dies contain matching

cavity contours, the punch containing the
positive contour and the die containing the
negative.
 However, coining dies may have quite different

cavities in the 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

Drawing operations
 Lancing
 Combined cutting and bending or cutting and forming

operation performed in one step to partially separate
the metal from the sheet.
 Can be used to make louvers in sheet metal air vents

for heating and air conditioning system in buildings.
 Twisting
 Twisting subjects the sheet metal to a torsion loading

rather than a bending load.
 It causes a twist in the sheet over its length using

conventional punch and dies which has been designed
to deform the part in the required twist shape. Lancing in several forms
a) Cutting and bending
 It is used to make products such as fans and propeller b) & c) Cutting and forming
blades.
Exercise
 A round disk of 150 mm diameter is to be blanked from a strip of

3.2 mm, half-hard cold rolled steel whose shear strength is
310MPa. Determine
a) The appropriate punch and die diameters

b) Blanking force
a) Punch and die diameter
The clearance allowance for half-hard cold-rolled steel is AC = 0.075

C  Ac  t  0.075  3.2m  0.24mm
Blank diameter = 150 mm, and the die size determines the blank size. Therefore,
Die opening diameter = Blank diameter = 150 mm
Punch size = Die opening diameter – 2C
= 150 mm - 2×0.24mm = 149.52mm

Exercise
 A round disk of 150 mm diameter is to be blanked from a strip of

3.2 mm, half-hard cold rolled steel whose shear strength is
310MPa. Determine
a) The appropriate punch and die diameters

b) Blanking force
b) The Blanking force
To determine the blanking force, we assume that the entire perimeter of the part is
blanked at one time. The length of the cute edge is
L   Db  150  471.12mm
Thus, the force is
F  StL  310  471.12  3.2  467.4 KN  53 tones

Article review
 Select one article, review and report a summary with a maximum of 5 Pages.
 The sustainability of neural network applications within finite element analysis in sheet metal
forming: A review
 Analysis and optimization of the surface waviness in the single-point incremental sheet metal
forming
 Experimental investigation on single point incremental forming of IS513Cr3 using response surface
method
 Prediction of the bending and out-of-plane loading effects on formability response of the steel sheets
 Advances in sheet metal forming analyses: dealing with mechanical anisotropy from crystallographic
texture
 Material optimization: A case study using sheet metal-forming analysis
 Development of multistage sheet metal forming analysis method.
 Springback Prediction in Sheet Metal Forming, Based on Finite Element Analysis and Artificial
Neural Network Approach
Deadline: February 8, 2022

References
 Metal Forming Analysis, R.H. Wagoner & J.L. Chenot, 2001; ISBN: 9780521642675.
 Mechanical metallurgy: George E Dieter.
 The Metallurgy of Welding, Brazing and Soldering – J.F. Lancaster, George Alien and Unwin Ltd., London.
 Fundamentals of Modern Manufacturing: Materials, Processes, and Systems - Mikell P. Groover - 4th Ed. – John Wiley &
Sons, Inc.
 Metal Forming: Mechanics and Metallurgy, WilliamF. Hosford, Robert M. Caddell, CUP 2007; ISBN: 0521881218,
9780521881210.
 Sheet Metal Forming Processes: Constitutive Modeling and Numerical Simulation, Dorel Banabic, 2010 ISBN:
978354881124.
 Sheet Metal Forming and Die Design, VukatoBoljanovic, 2004; ISBN: 0831131829, 9780831131821.
 Plasiticity for structural engineers -Chen
 PrinciplesofMetalWorking -R.Rowe-Amold London – 1965.
 S V Nadkarni, Modern Arc Welding Technology, Ador Welding Limited, 2010, New Delhi.
 Welding handbook, American Welding Society, 1987, 8th edition, volume 1 & 2, USA
 Manufacturing Technology (Foundry, Forming and Welding)-P.N.Rao, Tata Mc-Graw Hill.
 The Physics of Welding- L.F.Lancaster, Pergamon Press.
 Principles of Welding- R.S. Parmar.
 Welding Technology- O.P. Khanna, Khanna Pub.,
 Friction Stir Welding and Processing, Editors Rajiv S. Mishra & Murray W. Mahoney, ASM International, 2007
 Welding Engineering Rossi-Mcgraw Hill Publications
 Advanced welding processes-Nichodosco and shansky-MIR Publications.
 Welding for Engineers-Udin Funk and wulf.

MIEG 6421 - Sheetmetal Forming Processes

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MIEG 6421 - Sheetmetal Forming Processes

Uploaded by

Copyright:

Available Formats

FORMING & ADVANCED JOINING PROCESSES

Getasew Ashagrie (Ph.D.)

AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2

Module 3 Sheet metal forming processes

AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 3

About sheet metal

 Sheet metal working

 Typical sheet metal

 Thickness > 6 mm – sheet

 Most commonly used sheet

AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 4

Sheet metal forming

 Sheet metal is simply metal formed into thin and

 It is one of the fundamental forms used in

 Thicknesses can vary significantly, although

 The raw material for sheet metal manufacturing

 Typically, sheets of metal are sold as flat,

 The most common sheet metal working processes

Characteristics of sheet metal parts

Commercial importance of sheet

 Automobile and truck bodies,

AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 6

Sheet metal working – Terminology

 Press tools - Machine tools where most of

 Stamping press - A term used to

 Punch and die or stamping die – The

 Stampings - sheet metal products.

 Strips and coils – Sheet metal is often

AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 7

Three press working processes

 The three press working processes that cut

 Can be described as shearing, blanking

 Cutting operation along a straight line

 Performed on machines called power

 The upper blade of the power shears is

AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 8

Three press working processes

 Cutting of metal along a closed outline

 Blank is the part that is cut out, which

 Similar to blanking except that it

 The desired part is the remaining

AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 9

 Sheet metal cutting is accomplished by a shearing action between two sharp

Figure shows the shearing action

1. Just before punch contacts the work

AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 10

 Sheet metal cutting is accomplished by a shearing action between two sharp

 The shearing action is depicted in the four stop-sketch actions.

 As the punch begins to push into the work;

 Plastic deformation occurs in the surface of the sheet, then

AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 11

 Four regions: rollover,

AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 12

How can we minimize a Burr? Can we avoid it? Provide

AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 13

Engineering analysis of sheet metal cutting

 Process parameters in sheet metal cutting are:

 Distance between punch and die

 Typical values: 4% to 8% of the sheet metal

 The correct clearance depends on type of sheet

AAU / AAiT SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 14

Engineering analysis ...

 The effect of improper clearance (too small or