Sheet Metal Forming Processes

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Sheet Metal Forming Processes

• Manufacturing Processes

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Outline

• Introduction
• Shearing
• Blanking
• Bending
• Deep Drawing
• Stamping Dies
• Progressive Dies
• Transfer Dies
• Spinning

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Sheet Metal Working

• Products
• automotive fenders
• washers
• stamped parts
• channels

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Examples of Stamped Parts
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Examples of Stamped Parts
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Examples of Stamped Parts
This part was made from several stamped parts
plus a nut, which were stamped again to seal them
together
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Examples of Stamped Parts
This part was made from a sheet that was stamped,
bent, and welded into a tube, plus a separate
stamped end piece
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Examples of Stamped Parts
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Shearing

• A sheet-metal cutting operation along a straight
  line between two cutting edges

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Shearing of Metal Between Cutting Edges
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Shearing of Metal Between Cutting Edges
1/3 of material is cut and 2/3 of material
fractures
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Blanking

• Involves cutting the sheet metal along a closed
  outline

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Piercing and Blanking

• Shearing operations in which the shear blades are
  closed, curved lines along the edges of the punch
  and die
• In blanking, the piece punched out is the
  workpiece in piercing, the remaining strip is
  the workpiece

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Punch and Die
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Bending
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Bending
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Bending Springback
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Deep Drawing

• A sheet metal forming operation used to make
  hollow-shaped parts

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Deep Drawing
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Redrawing

• Additional drawing steps (redrawing) may be
  required if the shape change of the material is
  too severe

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Example of a Drawn Part
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Example of a Deep Drawing Press
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Stamping Die
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Stamping Die
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Progressive Die

• Performs multiple operations at different
  stations with every press stroke

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Progressive Die
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Example of Progressively Stamped Parts
This sheet has been stamped by a progressive die,
showing the series of operations from right to
left
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Progressive Die
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Progressive Die
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Progressive Die
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Progressive Die
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Progressive Die
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Progressive Die
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Examples of Stamping Machines
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Progressive Diein Stamping Press
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Progressive Die
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Material Coils
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Material Feed
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Material Feed
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Transfer Line
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Transfer Line
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Transfer Line
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Transfer Line
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Transfer Press
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Transfer Press
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Transfer Die
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Spinning

• Uses a spinning mandrel and a roller to form
  sheet metal into a radially symmetrical part

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Spinning
Courtesy Koch Metal Spinning
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Tube Spinning

• Uses a spinning mandrel and a roller to reduce
  the wall thickness and increase the length of a
  tube

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Summary

• Blanking, bending, and deep drawing are capable
  of producing an immense variety of thin metal
  parts
• Progressive dies can produce parts at high
  production rates by performing multiple
  operations simultaneously

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