Introduction to Manufacturing
Processes IME 211
Lecture (10) – Week (11)
Metal Forming Processes (III)
Couse Instructors
Mohamed Nassef, PhD
Associate Professor
IME Department
©INDUSTRIAL AND MANUFACTURING ENGINEERING
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DEPARTMENT, MOHAMED G NASSEF
Drawing Operations
ROD & WIRE DRAWING
Bulk Metal Forming Processes
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Drawing
❑ Drawing is an operation in which the cross-section of
solid rod, wire or tubing is reduced or changed in shape
by pulling it through a die.
❑ Drawn rods are used for shafts and spindles and as the
raw material for screws and studs.
❑ Drawing also improves strength and hardness when these
properties are to be developed by cold work and not by
subsequent heat treatment.
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(1) Wire Drawing
❑ Cross-section of a bar, rod, or
wire is reduced by pulling it
through a die opening
❑ Similar to extrusion except work
is pulled through die in drawing (it
is pushed through the die in
extrusion)
❑ Although drawing applies tensile
stress, compression also plays a
significant role since metal is
squeezed as it passes through die
opening
❑ The die angle has a great influence
on the drawing force and the
quality of the drawn product.
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(1) Wire Drawing (Cont.’)
❑ Wire drawing machines consisting of multiple draw dies (typically 4
to 12) separated by accumulating drums
❑ Each drum (capstan) provides proper force to draw wire stock
through upstream die
❑ Each die provides a small reduction, so desired total reduction is
achieved by the series
Fig: Continuous
drawing of a
wire
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(1) Wire Drawing (Cont.’)
❑
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(2) Tube Drawing
❑ Accomplished by pulling the stock through the sides of
the mandrel placed between dies
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عمليات تشكيل األلواح
Sheet Metal Forming
• SH EAR IN G
• BEN D IN G
• D EEP D R AW IN G
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Cutting (Shearing)
Operation
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Cutting (Shearing) Operation
❑ It is carried out on a press with
a punch having the same shape
of the required hole.
❑ Die contains a hole having the
same shape as the punch, but
slightly larger to give a
clearance.
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Cutting (Shearing) Operations
❑ In this operation, the workpiece is stressed beyond its ultimate
strength. The stresses caused in the metal by the applied forces will
be shearing stresses.
❑ The cutting operations include:
o Punching (Piercing)
o Blanking
o Notching
o Perforating
o Slitting
o Lancing
o Parting
o Shaving
o Trimming
o Fine blanking
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Cutting (Shearing) Operations
❑ Blanking: Blanking is the ❑ Punching (Piercing): It is a
operation of cutting a flat cutting operation by which
shape sheet metal. The article various shaped holes are made
punched out is called the blank in sheet metal. Punching is
and is the required product of similar to blanking except that
the operation. The hole and in punching, the hole is the
metal left behind is discarded desired product, the material
as waste. punched out to form the hole
being waste.
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Cutting (Shearing) Operations
❑ Perforating: This is a process by which multiple holes which are very
small and close together are cut in flat work material.
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Force required for shearing operation
Fs = s .L.t
Where:
s: Maximum shear strength of the material
L: circumference area (mm)
t: sheet thickness
• Example:
If a 15 mm hole diameter is required to be punched in a sheet metal
of thickness 10 mm. Find the force required to punch this hole if the
maximum shear strength of this metal is 400 MPa.
Fs = s .L.t
L = D = (15) = 47.12mm
Fs = 400 * 47.12 *10 = 188480N
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Bending
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Bending Operations
❑ The bending process
can be defined by the
plastic deflection of
the sheet metal around
a straight edge.
❑ The bending processes
can be applied to
sheets, plates and
tubes
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Bending Operations
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Bending Operations
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Deep Drawing
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Deep Drawing
❑ Deep Drawing: Drawing
operation is the process of
forming a flat piece of
material (blank) into a hollow
shape (Cup) by means of a
punch, which causes the blank
to flow into the die-cavity.
❑ Round sheet metal block is
placed over a circular die
opening and held in a place
with blank holder & punch
forces down into the die
cavity.
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Process description
D
h
http://www.custompartnet.com/wu/images/sheet-metal/deep-drawing-
sequence.png
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Calculation of Blank size
❑ Blank size of cylindrical parts:
𝐷2 . 𝜋 𝑑2 . 𝜋
𝑡= 𝑡 + 𝑑. 𝜋. ℎ. 𝑡
4 4
𝐷 = 𝑑 2 + 4𝑑ℎ
• Example:
If it is required to manufacture the sheet shells shown
in figure. Find the blank diameter D.
D = d 2 + 4dh
= (80mm) 2 + (4)(80)(90) 188mm
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