SHEET METAL

PRESSING PROCESSES
General manufacturing process

Casting process

Moulding process

Forging process

Machining process

Pressing process

Welding process

Painting process

Plating process

Heat treatment process

 Invention of printing press

Pressing process
 Pressing process

Definition of pressing process

It is the process by which the sheet metal is pressed (formed, pierced,

blanked, bent) to get the required shape and size

General presses part application

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 Why Sheet metal & Pressing process ?
 Ease of manufacture & less
process complexity

 Thin sections can be produced as

low as 0.2 mm

 High productivity & Cost effective

 Can be easily fabricated by joining

technology

 Superior strength and good

aesthetics if painted / plated
Types of Pressing operation

 There are as many as 23 pressing operations.

 Broadly classified as Cutting operation and Forming operation

Cutting operation Forming operation

Blanking Piercing Bending Forming

Fine blanking Cutting off Drawing Flaring

Parting off Trimming Embossing Coining

Shaving Perforating Extrusion Bulging

Lancing Dinking Curling Swaging
Broaching Notching Planishing Rolling
Types of Pressing operation

 Few general pressing operations are

Pressing process

Blanking Piercing Trimming Fine Parting off

Blanking

Bending Forming Drawing Embossing Flaring

Etc.,
What is Shearing ?

 It is a method of cutting sheets or stocks without forming chips

 The material is stressed in a section which lies parallel to the forces

applied ( by means of shearing blades or Punch & Die )

Punch
Punch
Sheet
Sheet
Die
Critical stages of shearing
 There are three stages of
shearing
Penetration Fracture
 Plastic deformation
Plastic
 Penetration deformation

 Fracture
Peak load

Punch

Stress
Sheet

Die
t
What is Blanking ?
 It is a shearing operation, which involves elastic and plastic
deformation and fracture

 The material is stressed beyond its ultimate strength between two

cutting edges

Blanking
Punch punch

Sheet

Scrap

Die

Output
product
What is Piercing ?
 It is also a shearing operation similar to the blanking process.

 The difference between Blanking and piercing is,

 In blanking, the cut out piece is the required material &

 In piercing, the cut out piece is scrap material / slug.

Piercing Blanking
punch punch

Scrap

Scrap Required
part

Input Process - 1 Process - 2

raw material Piercing operation Blanking operation
What is Cutting off ?
 A cutoff operation creates a part
from the sheet stock with a single
cut.

 Each cut separates another part

 Cutoff lines may be straight,

curved, or jagged

Why cutting off operation ?

 No material scrap in Cutoff

operation
Cutting off

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Cutting off

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Cutting off

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What is Parting off ?
 Parting is very similar to a cutoff,
except two simultaneous cuts are
required instead of one.

 A parting operation leaves a

small amount of scrap between
blanks

Why Parting off operation ?

 Material saving at the sides
compared to Blanking operation
Parting off

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Fine blanking
 After a typical blanking operation,
the edge of the blank has two
distinct portions. The Smooth
portion and the Rough portion

 The rougher portion, flatness, edge

squareness and edge condition are
often undesirable for parts like gear
teeth, cam faces, drive chains etc.,

 Hence fine blanking is preferred for

these type of parts which has 10%
lesser cutting clearance than
ordinary blanking
What is Fine blanking?
 In Fine blanking V-shaped
projections compress the metal
slightly away from the cut while the
punch shears the metal.

 The result is an edge that is

entirely smooth ( up to 0.015 mm )

 Fine blanking can produce hole

diameter as little as 40 - 50% of
material thickness
What is Shaving operation?
 The cutting clearance between
punch and die will be less than the
ordinary blanking which lead to
shaving of metal.
 Shaving finishes a previously cut
edge by shearing off the small
amount of the remaining rough
portion
Why Shaving operation ?
 Shaving increases accuracy and
smoothness.

 Alternate to fine blanking process

for certain parts
What is Trimming operation ?
 It is a shearing operation which
removes the excess unwanted
material from a drawn part

Why Trimming operation ?

 To remove the excess drawn part

to get desired shape and clean
finish part
Trimming

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Trimming
What is Lancing operation?
 Shearing an interior portion of the
sheet to create a bent tab that
remains attached on one end is
Lancing
What is Notching operation?
 Notching removes a portion of
metal from the side.

 In this example, notch appears as

part of the outer edge of the final
blank.
 Perforating
Punching a close arrangement of a large
number of holes in a single operation.
Perforating
 Similar to piercing operation carried-out
on full width of sheets or parts with rows
of punches and dies arranged in a line
or in a staggered / profiled manner

Various types of
perforated sheets
Perforated
paper(Stamps)

Filter housing made

of perforated sheet
g

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Nibbling.

Punching a series of small overlapping slits or holes along

a path to cut out a larger contoured shape.
Eliminates the need for a custom punch and die but will
require secondary operations to improve the accuracy and
finish of the feature.
Dinking .
A specialized form of piercing used for punching soft metals.
Hollow punch, called a dinking die, with beveled,
sharpened edges presses the sheet into a block of wood or
soft metal.
 Louvering

 Louvering is an operation
involving shearing and
forming in a single stroke

 No scrap is generated
in this process

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12) Lancing

 Shearing an interior portion of

the sheet to create a bent tab
that remains attached on one
end is Lancing.

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What is Bending operation?
 It is the straining of metal around
a straight axis, with very little
change in thickness

 During bending, the inside of the

bend compresses along the axis
of bend & the outside of the bend
stretches instead.

 Metal flow is uniform along the

bend axis
What are the types of Bending operation?
 Two main methods for sheet bending are
 V-bending
 Edge bending
What is Forming operation?
 It is similar to bending except the
line of bend is along the curved
axis instead in a straight line.

 The metal flow is not uniform as in

bending and it depends on the
shape of the component.
What is Drawing operation ?
 It is the process used for making
hollow cylindrical shapes from a
flat sheet metal

 During drawing the sheet

experiences a variety of forces
and severe plastic deformation

 Drawing is very sensitive to

material imperfections, die
misalignments, etc.
What are the types of Drawing operation?
 Two methods for drawing operations

 Simple Drawing

 Deep drawing

Simple Drawing Deep drawing

What is Embossing operation?
 Embossing compresses sheet
metal against a patterned die in
order to create a raised surface

 In embossing the upper and lower

die shapes match

 No thickness variation in part

Why Embossing operation ?

 Creating ribs by embossing add

strength to the sheet metal
What is Coining operation?
 It is similar to embossing

 The key difference with embossing

is in the shape of the die. The
upper die and lower die shapes
does not match

 The thickness of the part varies

Why Coining operation ?

 To create different impressions /

embossing on the part
Bulging operation
 It is an internal forming operation
used to expand portion of a drawn
tube

 The forming force is applied from

inside work piece and transmitted
through medium (rubber, oil or water)

Why Bulging operation?

 It is done in order to facilitate

assembly or joining operation.
Flaring or Lugging operation
 It is similar to bulging operation.

 The process of flaring is forming

an outward flange on parts using a
flaring tool

Why Flaring operation ?

 It is done in order to facilitate

assembly or joining operation.
What is Swaging or Necking operation?
 Necking is exactly opposite of
bulging

 Its is an operation of compressing

a section of the cylinder to reduce
its diameter.

Why Necking operation ?

 It is done in order to facilitate

assembly or joining operation.
 20) Collar Drawing
• Flanging or collar drawing is a process in which a collar
is formed so that more number of threads can be
provided.
• The collar wall can also be used for as rivet when two
sheets are to be fastened together.
 20) Collar Drawing

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C draw.pptx
Curling or Beading
 A common operation used to shape
the rim is curling.
 Curling turns the edge of the rim on
itself.
 The curling process may take two or
more steps to create the final curved Fender part

edge.
Why Curling operation ?
It adds stiffness at the edge and
improves the appearance of the part Curling

and for safe handling.

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Curling
 Curling and coiling-up is done by the pressure of the
punch face with a semi-round recess.

 The edges of drawn or pressed parts are coiled up in

press tools such as shown in fig.

 At the initial contact between the punch and the blank

the edge is bent; with the further stroke of the
press-slide the final coiling is done.

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Curling
 WIRE

Wire inside the curl

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Swaging or Necking

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What is Curling operation?
 A common operation used to
shape the rim is curling.

 Curling turns the edge of the rim

on itself

 The curling process may take two

or more steps to create the final
curved edge

Why Curling operation ? Fender part

 It adds stiffness at the edge and

improves the appearance of the
part and for safe handling
Curling
What is Flanging operation?
 It is an operation that creates a 90°
bend

 A flange can be straight or curved.

 A stretch flange bends inward, and

a shrink flange bulges out.

Why Flanging operation ?

 It strengthens an edge of the part

 Also facilitates self location guide

Fuel tank inner
for next assembly parts
What is Hemming operation?
 Hemming bends and folds the
edge of sheet metal back upon
itself

 It is sometimes called flattening.

Why Hemming operation ?

 It increases stiffness, improves
appearance, and removes any
sharp edges.
What is Seaming operation?
 Seaming joins the edges of two
separate sheets of metal together
by folding them over one another

 A seam is essentially two

interlocking hemming operations.

Why Seaming operation ?

 It is often used to create
cylindrical containers from a
single sheet.
What is Planishing operation?
 It is used to straighten the blanked
component.

 Very fine serration points

penetrate all around the surface

Why Planishing operation ?

 Releases stress and improves the
straightness of the component
Planishing

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What is Rolling operation?
 It is a pressing operation

 the metal sheet is deformed

continuously in a linear manner by
passing it through a consecutive
series of rolls

 The rolls with predetermined

profile produce the shape

Why rolling operation ?

 Reduce tool cost and component
cost
Wheel
 Process simplicity rim
Exercise

Name the pressing operation

1. Identify the operations performed

Pin planishing 2 Notching

4 Bending

1 Piercing
2. Identify the operations performed

Flanging 2 Trimming

Embossing
1 3
3. Identify the operations performed

Flanging 1

2 Forming
Key process controls
 Key process controls

S# Parameter Why To Control Application Details

1 Ram stroke • To ensure sufficient ram travel for All operations

adjustment pressing operation
• To achieve proper shut height
– to avoid tool overload
– to ensure full bottoming of the part

2 Proper • To avoid tool overload All operations

Clamping of Die • To avoid pillar / bush bend / breakage

3. Die cushion • To avoid wrinkles in the part Forming & deep

pressure drawing operations
Summary

 Pressed parts are opted for its ease of manufacture, less process
complexity, cost effectiveness, fabrication friendly, Superior strength
etc.,
 There are as many as 23 press operation approximately. Of which
blanking, piercing, Forming, Bending, Drawing, Trimming etc., are
familiar press operations
 There are three stages of shearing Plastic deformation, Penetration
and Fracture
 Key process control parameter are ram stroke, tool clamping,
Die cushion pressure etc.,
Pressing terminologies
 Pressed Part Design is Optimum, when :

It permits maximum productivity

Least maintenance (Burr….)

Lowest feasible life time cost(Die life?)

Maximum Utilization of the least expensive material (Q) that

will function satisfactorily(Fuel Tanks)

Most efficient press-working practices

Meets sales & service requirements of shape, size, strength,

finish, style & utility

Does not call for die modifications

 SHEET METAL PRESSING /
STAMPING

•Method of cold-working sheet metal to a prescribed

size & shape by means of a die & a press.

•Die determines size & shape of completed

workpiece.

•Press provides force needed to effect change

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Thank you