METAL FORMING

PROCESSES
ASSIGNMENT PRESENTATION
COURCE CODE : 15P504
GUIDED BY R.MOHANRAJ SIR [ DEPARTMENT OF PRODUCTION
ENGINEERING]
TOPIC : DEEP DRAWING,SHEARING,STRETCH FORMING,METAL
SPINNING
PRESENTED BY
S.ARAVIND[18P604]
D.ASHWIN[18P608]
S.SASIKUMAR[19P905]
K.KARTHIKEYAN[19P910]
DEEP DRAWING
• The deep drawing process
is a forming process which
occurs under a
combination of tensile and
compressive conditions.
• A flat sheet metal blank is
formed into a hollow body
open on one side or a
hollow body is formed into
a hollow body with a
smaller cross-section.
WORKING PRINCIPLE
 MATERIALS
• Stainless Steel used to corrosion, high
temperatures, and low temperatures — as well as
high strength, strong aesthetic appeal, and ease of
fabrication.
• Aluminum 1100-0, 3003-0, 5052-0, and 6061-0
• These aluminum alloys feature good drawability,
very good corrosion resistance, and low cost.
Aluminum 6061-0 can be heat treated for higher
strength.
 MATERIALS
 Brass 85/15 and 70/30
• Brass 85/15 (red brass) and 70/30 (yellow cartridge
brass) have good drawability and solderability, making
them a good substrate for hot solders or tin plates.
 Cupro Nickel 715
• Cupro Nickel 715 alloy has good drawability and very
good corrosion resistance; it is often used to aerospace
relay cases.
 Nickel Silver Alloy 2
• Used for relay cases, nickel silver alloy 2 has good
drawability and good solderability.
EQUIPMENTS AND MATERIALS
• Softer materials are much easier to deform and
therefore require less force to draw.
• Punches and dies are typically made of tool steel,
however cheaper (but softer) carbon steel is
sometimes used in less severe applications.
• It is also common to see cemented carbides used
where high wear and abrasive resistance is present.
• Alloy steels are normally used for the ejector system
to kick the part out and in durable and heat
resistant blankholders
 DRAWING FORCE CALCULATION
• Drawing force: Fd,max = n*π*d*t*UTS
• Example: Cup diameter: d= 45.7 mm
• Sheet thickness: t = 0.5 mm
• Ultimate Tensile Strength= 320 Mpa
• Drawing coefficient: n = 0.7…0.95
Fd,max = 0.9*π*45.7*0.5*320 =20 674 N
DRAWING FORCE FOR MATERIALS

Percent reduction
Blank
Materials
39% 43% 47% 50%

Aluminium 88 101 113 126

Brass 117 134 151 168

Cold-rolled
steel 127 145 163 181

Stainless 166 190 214 238

steel
 ANALYSIS OF DEEP DRAWING
• It has different effectible process parameters from
which an optimum level of parameters can be
identified so that
• An efficient final product with required mechanical
properties will be obtained.
• The present work is to evaluate the formability of
different metal sheets using deep drawing process
• In which effects of different sheets and die/blank
holder angle on deep drawing process observed for
sheet metal of 0.8mm of SS304 and Brass and 0.9
mm of Al.
 ANALYSIS OF DEEP DRAWING
• The experiments were performed by designing the
deep drawing tools such as die, blank holder, and
punch.
• In addition, the numerical simulations are
performed for deep drawing of cylindrical cups
using three levels of previously mentioned.
• Punch forces and dome heights are evaluated for
all the conditions.
 ANALYSIS OF DEEP DRAWING
• From this work, the formability for different metal
sheets is observed for angular geometries of deep
drawing tools.
• Moreover, it is observed that strain formation is
more for the brass sheet and stress is more for
aluminium sheets.
 IMPORTANT PARAMETERS
Blank Holding Down Parameter
Drawing Ratio
Radial Clearance between punch and die
Die Profile Radius
Punch Profile Radius
Punch Force
 ADVANTAGES OF DEEP DRAWING
• Speed.
• Eliminates assembly steps.
• Seamless.
• High accuracy.
• Produces complex geometries.
• Produces very strong parts.
 DISADVANTAGES OF DEEP DRAWING
• it isn't valued as effective in small quantities.
• The cost of press setup is remarkably high
• It requires significant experience and
expertise
• It is more expensive for short runs.
SHEARING
• Shearing is a metal
fabricating process used to
cut straight lines on flat
metal stock.
• During the shearing process,
an upper blade and a lower
blade are forced past each
other with the space
between them determined
by a required offset.
• Normally, one of the blades
remains stationary
WORKING PRINCIPLE
 MATERIALS FOR SHEARING
• Low alloy steel is used in low production of
materials that range up to 0.64 cm (​1⁄4 in)
thick
• High-carbon, high chromium steel is used in
high production of materials that also range
up to 0.64 cm (​1⁄4 in) in thickness
• Shock-resistant steel is used in materials that
are equal to 0.64 cm (​1⁄4 in) thick or more
 TOLERANCE AND SURFACE FINISH
• When shearing a sheet, the typical tolerance is +0.1
inch or −0.1 inch but it is feasible to get the
tolerance to within +0.005 inch or −0.005 inch
• While shearing a bar and angle, the typical
tolerance is +0.06 inch or −0.06 inch but it is
possible to get the tolerance to +0.03 inch or −0.03
inches
• Surface finishes typically occur within the 250 to
1000 micro inches range, but can range from 125 to
2000 micro inches
SHEAR CUTTING FORCE FORMULA
• Formula for calculating the cutting force
is
Cutting force = L x S x T max
• L = Length of periphery to be cut in ‘mm’.
• S = Sheet thickness in ‘mm’
• T max = Shear strength in N/mm
 SHEARING FORMULAE
• Cutting force = L x S x T max
• Press force = Cutting force + Stripping force
• Striping force = 10% to 20% of cutting force
• Calculate the press force required to produce
the following component.
• Sheet thickness 2mm.
• Material is brass.
 SHEAR CUTTING FORCE PROBLEM
1. Cutting force =L x S x T max
= 126 x 2 x 400
= 100800 N
= 100.8 KN
2. Press force = Cutting force +Stripping force
=100800 + 20% 100800
=120960 N
=120.960 KN.
 ANALYSIS OF SHEARING
 AIM
It discusses investigations on the influence of the
shearing ratio, tool size to material thickness,
conditions of fine-blanking applied for fabricating
precision parts such as shape of the blankholder and
blank holding force, as well as details on material flow
and strain distribution.
 ANALYSIS OF SHEARING
• By applying the Fourier phase correlation methodto
the viscoplasticity method, an analysis method for
obtaining accurate material flow and strain
distribution in a short time has been established.
• This method does not require the marking
procedure of the material surface that was formerly
indispensable
• It is able to treat large deformations.
• It is therefore expected to contribute to a wide
range of material deformation researches.
 ANALYSIS OF SHEARING
• Investigations on the influence of the processing
conditions in the ordinary shearing process showed
quantitatively that the strain concentrates around
the clearance vicinity for small clearances
• Development of analyzing system applicable for
large plastic deformation
 IMPORTANT PARAMETERS
Punch-Die Clearance
Force Required
Beveling Angle of Punch
Die (Angular clearance)
Stripping Force.
 ADVANTAGES OF SHEARING
• Incredibly fast, with shearing cutting through sheet
metal in just seconds.
• Creates clean cuts with smooth edges.
• Can be performed on sheet metal in a variety of
diameter sizes.
• Cost-effective for high-volume manufacturing
applications.
• Doesn't produce waste in the form of chips.
DISADVANTAGES OF SHEARING
• Not ideal for low-volume manufacturing
applications.
• Exceptionally hard metals like tungsten cannot
be sheared.
• May cause deformity in sheet metal.
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
contoured parts.
• It is performed on a stretch
press, in which a piece of
sheet metal is securely
gripped along its edges by
gripping jaws.
WORKING PRINCIPLE
STRETCH FORMING SPECIFICATION
 ANALYSIS OF STRETCH FORMING
• Computer Aided Calculation for determine the
forming depth, punch load and strain distribution
during punch stretching is proposed.
• The results predicted by the program were
compared and agree well with experimental results.
• Stretch forming of steel and aluminium blanks using
hemispherical and rectangular punches was
analysed
 ANALYSIS OF STRETCH FORMING
• The influence of sheet thickness, variations in
mechanical properties, friction conditions and die
geometry were investigated.
• The formability of low-carbon steels, high-strength
steels and Aluminium alloys are discussed and a
new criteria to predict the stretchability of sheet
metal is pointed out.
 IMPORTANT PARAMETERS
Sheet Thickness
Variations in Mechanical Properties
Friction Conditions
Die Geometry
Forming Depth
Punch Load
Strain Distribution during Punch Stretching
 ADVANTAGES OF STRETCH FORMING
• Hardness is increased by approximately 2%.
• Springback is greatly reduced.
• Residual stresses are low in stretch-formed
parts.
• Easy and fast tool changeover
• Low cost forming
• Finished product matching the shape of the
tool
 DISADVANTAGES OF STRETCH FORMING
• Middle region of sheet not sufficiently formed
so that strain distribution in sheet cross
section is not uniform
• This leads to one hand to a spring back and
consequently a loss in dimensional accuracy
and other hand to insufficient work hardening
METAL SPINNING
• It is a metalworking
process by which a disc
or tube of metal is
rotated at high speed
and formed into an
axially symmetric part.
• Spinning can be
performed by hand or
by a CNC lathe.
WORKING PRINCIPLE
ANALYSIS OF METAL SPINNING
• An analysis of spinning is presented which shows
how the strains involved are quite different
resulting in different spinning techniques.
• Material Used :Virtually any ductile metal may be
formed; ranging  from aluminum or stainless steel
to high-strength, high-temperature alloys.
• Equipment Used : By hand or by CNC Lathe.
• Restrictions: Diameter and depth of formed parts
are limited only by the size of the equipment
available
ANALYSIS OF METAL SPINNING
• Volume: Typical production runs of 1,000 pieces or
less For prototype and limited production quantities
Typical volume range  50,000 units per year
• Industry for Use: All industry
• Standards Met: Customer specifications
• Process of metal spinning is capable of forming
workpiece with thickness of 0.5 mm to 30mm
• Blank Materials used are Aluminium, Brass,
Stainless Steel, Copper etc
 BLANK MATERIALS USES
• Aluminium: It is elastic in nature and does not
required any heat treatment
 1100- H14 99% Al and 1%
alloy[60%]
 3003- H14 98% Al, 0.12% cu and
1.2 % Mn [30%]
 5052- H32 97% Al, 2.5% mg, 0.25%
Cr [25%]
 6061- T6 25%.Aluminium
 BLANK MATERIALS USES
• Stainless steel - It is also in elastic nature and
stretch before tearing .The percentage elongation
is 50 -68%
• Copper - it is good in formability and have
double its tensile strength when work hardened.
It contains 99% Cu. The percentage of elongation of
copper is about 60%.
• Brass - It require the more force to deform and it
works hardens less. It contains 65% Cu and 35% Zn.
the percentage of elongation of brass is 64%
FORCE FORMULA AND PROBLEM
 ADVANTAGES AND DISADVANTAGES
• Comparable to Drawing • More Time Required
Process • More Skill Required
• Economical Process • Not Suitable for Large-
• Best Suited for Large Scale Production
Parts
• Complicated Shapes
Produced
• No Investment in Die
Making
• No Finishing Operation
 IMPORTANT PARAMETERS
Blank thickness Temperature
Blank Diameter Lubricant
Roller Nose Radius Bearing Selection for
Roller Diameter Roller
Force Mandrel Design
Feed Ratio
Feed Rate
Spindle Speed
 REFERENCE
• Material flow analysis on shearing process by
applying Fourier phase correlation method -
Analysis of piercing and fine-blankin by Isamu
Aoki and Toshinori Takahshi
• Science Direct Articles for Respective
processes
• Research Gate Articles For Respective
processes
THANK YOU ALL
FOR YOUR KIND COOPERATION