SHEET METAL

Different Manufacturing Processes

Introduction : Forming Process

a. Bulk Forming Process
b. Sheet Forming Process * Metal Forming
Technology by Dixit

3.

Forming Techniques * Basics of Forming 2

4.

Sheet Metal Characteristics

5.

Different Processes for fabrication of Sheet Metal

TARA Scope

7.

TARA Equipment

Manpower Qualifications

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As described in DIN 8580 Manufacturing

processes are classified into six main groups :
1. Primary Shaping process

2. Forming process
3.
4.
5.
6.

Dividing process
Joining process
Modifying Material Properties
Coating

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 Forming means that the given form of solid structure is formed into another
shape without changing the weight or material composition.
Forming means bending and/or Stretching a material beyond its elastic limit to
permanently change the shape.
Forming Process are characterized as chipless or non-material removal
processes
What is the difference between Foil, Sheet & Plate?
Foil :
Sheet :
Plate :

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t 0.0059
0.0059 < t 0.25
t > 0.25

 Sheet metal forming processes are those in which force is applied to a piece of
sheet metal to modify its geometry rather than remove any material. The applied
force stresses the metal beyond its yield strength, causing the material to
plastically deform, but not to fail. By doing so, the sheet can be bent or
stretched into a variety of complex shapes.
Point A
Point B
Point C
Point E
Point F

Proportional Limit
Elastic limit
Yield Point
Tensile Strength
Fracture Point

Stress Strain Diagram Ductile Material

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 Bulk deforming processes can be classified as

primary or secondary processes
Primary processes reduce a cast material into slabs, plates,
and billets
Secondary processes reduce shapes into finished or semifinished products

Bulk deformation processes are those processes

where the thickness or cross sections are reduced
Sheet-forming process involve the deformation of
materials whose thickness and cross section remain
relatively constant

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 Rolling
Forging
Extrusion
Wire, rod, and tube drawing
Cold forming, cold forging, and impact extrusion
Piercing
Squeezing processes

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Rolling operations reduce the thickness or change the cross section of a

material through compressive forces
Often the first process that is used to convert material into a finished
wrought product
Thick stock can be rolled into blooms, billets, or slabs

Metal is passed between two rolls that rotate

in opposite directions
Friction acts to propel the material forward
Metal is squeezed and elongates to
compensate for the decrease in crosssectional area
Hot Rolling & Cold Rolling

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Figure Flow chart for the

production of various finished
and semifinished steel shapes.
Note the abundance of rolling
operations

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 Processes that induce plastic deformation through localized compressive

forces applied through dies
Oldest known metalworking process
Parts can range in size
Methods
Drawing
Upset
Squeezed in closed impression dies

Figure: Double-frame drop hammer

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Figure : (Top) Illustration of the unrestrained flow of material

in open-die forging. Note the barrel shape that forms due to
friction between the die and material. (Middle) Open-die
forging of a multidiameter shaft. (Bottom) Forging of a
seamless ring by the open-die method. (Courtesy of Forging
Industry Association, Cleveland, OH.)
10

Metal is compressed and forced to flow through a

shaped die to form a product with a constant
cross section
May be performed hot or cold
A ram advances from one end of the die and
causes the metal to flow plastically through the
die
Commonly extruded metals: aluminum,
magnesium, copper, and lead
Figure Direct extrusion schematic showing the
various equipment components

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11

Reduce the cross section of a material by pulling it through a die

Similar to extrusion, but the force is tensile

Figure Schematic drawing of the rod-or bardrawing process.

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Figure Cold-drawing smaller tubing from

larger tubing. The die sets the outer
dimension while the stationary mandrel sizes
the inner diameter.

12

Sheet metal processes can be broken down into two major classifications and one
minor classification:1. Shearing processes -- processes which apply shearing forces to cut, fracture, or
separate the material.
2. Forming processes -- processes which cause the metal to undergo desired
shape changes without failure, excessive thinning, or cracking. This includes
bending and stretching.
3. Finishing processes -- processes which are used to improve the final surface
characteristics.

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 Sheet metal subjected to shear stress developed between a punch and a die is
called shearing
Shearing usually starts with formation of cracks on both the top and bottom
edges of the work piece (Point A,B,C,D). These cracks meet each other and
separation occurs
Clearance, c, between the Punch &
die typically between 2% & 10% of
Sheet Metal thickness.
As clearance increases, sheared
edges becomes rougher and zone of
deformation becomes largerclearance are smaller for softer
metals, thinner sheets.

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 Punching: shearing process using a die and punch where the interior portion
of the sheared sheet is to be discarded.
Blanking: shearing process using a die and punch where the exterior portion
of the shearing operation is to be discarded.
Perforating: punching a number of holes in a sheet
Parting: shearing the sheet into two or more pieces
Notching: removing pieces from the edges
Lancing: leaving a tab without removing any material

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 Routing is an operation of Profile cutting of

Sheet metal.
It can be done by conventional machine or CNC
machines
Sheets are placed over the bed of routers by
using clamping screws and the spindle rotates
at high rpm and moves in X, Y direction to cut
the profile.
Cutting tool used in Routing machine is Router
Bits (Single flute or Double flute)
Both Drilling and profiling can be performed
with one spindle simultaneously
Very little Z movement
New Generation Machines have the capability
of stacking the sheets without mechanical
clamping methods of screws. Vacuum tables
are being used to hold the sheet down.

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2.1 Bending: forming process causes the sheet metal to undergo the desired
shape change by bending without failure.

Common die bending operations

Various bending operations

2.1.a. Brake Press Forming

2.1.b. Hydro Forming / Flex forming
2.1.c. Rolling

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Bend line - The straight line on the surface of the sheet, on

either side of the bend, that defines the end of the level flange
and the start of the bend.
Outside mold line - The straight line where the outside surfaces
of the two flanges would meet, were they to continue. This line
defines the edge of a mold that would bound the bent sheet
metal.
Flange length - The length of either of the two flanges,
extending from the edge of the sheet to the bend line
Mold line distance - The distance from either end of the sheet
to the outside mold line.
Setback - The distance from either bend line to the outside
mold line. Also equal to the difference between the mold line
distance and the flange length
Bend axis - The straight line that defines the centre around
which the sheet metal is bent.
Bend length - The length of the bend, measured along the bend
axis.
Bend radius - The distance from the bend axis to the inside
surface of the material, between the bend lines. Sometimes
specified as the inside bend radius. The outside bend radius is
equal to the inside bend radius plus the sheet thickness.
Bend angle - The angle of the bend, measured between the
bent flange and its original position, or as the included angle
between perpendicular lines drawn from the bend lines.
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18

 Press Brake forming is a process in which a blank or work piece is placed over a
straight open die and is deformed down into a die by a punch actuated by the
Ram

Equipment Sub Assemblies

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19

Common terminology used in Press Brake:

1.
2.
3.
4.
5.
6.
7.
8.

Upper Tool(Punch)
Work piece
Inside Work piece Radius (Ri)
Outside Work piece Radius(Ro)
Die Width(W)
Lower Tool Radius
Upper Tool Radius
Lower Tool

Type of bending
in Press Brake :
1. Air Bending or
3 Point
Bending
2. Bottoming or
Coining
3. Hemming
4. Folding
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Folding

Hemming

20

Hydroforming - Medium of forming

water / Hydraulic oil
Sheet hydroforming uses one die and a sheet of
metal; the blank sheet is driven into the die by
high pressure water/oil on one side of the sheet
forming the desired shape
Also called:
[Link] Process
[Link] Wheelon Process

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21

Flex forming is much similar to that of the Hydroforming but a Bladder or a

Rubber pad is places in between the Sheet and the hydraulic medium which acts
as the punch and a draw/form is produced

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22

Basic Flex Forming press components

Process of Flex forming

Key Parameters of Equipment

Model

QFC 1.1x 3 -1000

QFC 1.2x 3 -1000

Make

AVURE

AVURE

Type

Fluid Cell

Fluid Cell

No. of Tables /Trays

Tray Size(mm)

3000x1100

3000x1200

Max. Pressure (bar)

1000

1000

Pressure Range (bar)

50-1000

50-1000

Nominal Tool Height (mm)

115-230

115-245

Cycle Time (including Table

transfer)

90 Sec

105 Sec

Pad/ Bladder Type

Polyurethane bladder

Polyurethane bladder

Pad/Bladder Life(Cycles)

15000

15000

Auto Pad Changer

No

No

Hydraulic Medium

Castro Oil

Castro Oil

Control System

Siemems PLC

Siemems PLC

Cooling SyStems

External

External

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Tray In

Align Tray

Prefilling

Pumping

Intensifying

Holding

Decompression

Evacuation

Tray out
24

Advantages of Flex forming / hydroforming:

Tooling Cost is very less

Multi part Forming can be Performed

Complex Shape Forming is Possible

High Productivity

Smooth finish (Draw Marks are avoided)

Very Low operating cost

Versatile Process (Forming from 0.1mm to 16 mm)

Faster Tool Setup

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25

What is Rolling?

Rolling is a metal forming process in which metal

stock is passed through a pair of rolls to achieve the
required radius or diameter through out the length
of the part.

The machine used to roll the sheet metal stock

called as rolling machine.
Why Rolling?
To avoid the tooling cost involved to make the form
blocks.
To Production lead time is less comparing with
other types of forming methods.
To get the good Surface finish of the final product.

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6
1.
2.
3.
4.
5.
6.
7.

Upper Roll (VS)

Left Lower Roll (X)
Right Lower Roll (L)
Control Panel
Tilting Support
Hydraulic tank
Main frame

26

1. Squaring

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2. Pre-bending

3. Rolling to desired diameter

27

2.2 Stretching: forming process causes the sheet metal to undergo the
desired shape change by stretching without failure
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.
The basic principle of this technology is to stretch the metal beyond its yield
point in order to reach the plastic area so that the elongation is permanent.
By stretching the metal there is no compressed fibre thus much less spring back
This principle can be applied to metal sheets and profiles and in various directions
depending on the final part shape.
Force required to Stretch

F = 0,1S * (UTS+YP) / 2
S= Profile section in mm2
UTS = Ultimate tensile strength(MPa)
YP = Yield Strength (Mpa)
F = Stretching force daN

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 Process of Stretch forming

1. Loading
2. Pre-stretching
3. Stretching & Unloading

The profile is gripped at both ends between 2 interchangeable gripping Jaws. The
material is plasticized by application of tensile stress > yield point , this first stage is
achieved by Stretching (tension) cylinders. The profile is the stretched and wrapped
around the tool, this second stage is achieved by combination of Stretching and Arm
(Wrapping) Cylinders.
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7/9/2014

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Total P/N 2004

Part Qty. - 2728

FY 14-15 : 38 SS

Process Category

Qty./SS

3 Axis-Route

2345

5 Axis-Route

26

Nibbler

297

Deburring

2722

Rubber press

999

Brake press

843

Roll forming

99

Hand forming

238

Hydraulic Press

66

Drilling

115

Chem Mill

160

Mech Mill

15

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908 Series - Part Summary

808 Series - Part Summary

Unique Part
Qty
Number

[Link]

Process Category

BP Only

16

40

HP Only

16

Nibbling Only

Rolling Only

18

19

Rolling+5 Axis+VMC 3A

Routing Only

14

39

RP+BP

RP+HP

RP+Rolling

10

RP Only

34

61

11

Routing + Chamfering

12

Nibbling+Rolling

Grand Total

98

197

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[Link]

Process Category

Unique Part
Number

Qty

1
2
3

BP Only
Rolling Only
RP Only
Grand Total

2
8
7
17

5
8
8
21

Total P/N 115

Part Qty. - 218

32

Process Category
Nibbling
Nibbling, BP
Nibbling, BP, CSK
Nibbling, BP, HP
Nibbling, CSK
Nibbling, HP
Nibbling, RP
Nibbling, RP, HF
Nibbling, RP,BP
Routing
Routing, BP
Routing, BP, CSK
Routing, BP, HF
Routing, BP, RP
Routing, BP, RP, Welding
Routing, HP
Routing, RP
Routing, RP, BP, HF
Routing, RP, Drilling
Routing, RP, HF
Grand Total
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Part Number
8
14
2
4
6
1
5
4
2
11
19
3
2
6
2
2
2
1
1
3
98

Total P/N 98

33

Total P/N 1676

Process Category
3-Axis, 5-Axis, Rolling
BP
BP-HF
HP
Nibbler Only
Nibbler+BP
Nibbler+RP
Query
Rolling
Rolling-BP
Routing Only
RP
RP-BP
RP-HF
Grand Total
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Part
Number
7
218
8
7
4
10
2
128
8
1
191
331
8
19
942

Process Category
Cutting Only
Cutting-5 Axis
Cutting-Chamfering
Cutting-Chamfering-5 Axis
Cutting-Drilling
Cutting-Drilling-Chamfering
Cutting-Drilling-Chamfering-HP
Cutting-Drilling-Chamfering-Joggeling
Cutting-Drilling-HP
Cutting-Drilling-Joggeling
Cutting-HP
Cutting-Joggeling
Cutting-Joggeling-5 Axis
Cutting-Joggleing
Query
Grand Total

Part
Number
9
97
4
3
191
86
36
12
9
33
1
1
41
1
186
710
34

Line item

M/C Name

Make

Model

Qty

Capability

Thermwood

C53

Bed Size: 5 X 10

Trumpf

TruPunch 5000

Bed Size: 5 X 10

3 Axis CNC Blank routing machine

5 Axis CNC Nibble/Punch Press

5 Axis Drilling and Routing Machining Center

Thermwood

M67-55DT

Bed Size : 5 X 5 Dual

Table

3 Axis machine ~ 4000 mm long bed

Thermwood

C53

Bed Size: 5 X 10

25

3 Point Bending Machine - Press Brake

Cincinnati

230AS10/12

Max bed Length = 126"

Stroke Length = 10"

36

Rolling machine - 3660mm wide

Davi

MAV-3-HDC AER
4027/S

3.6 m wide rollers

40

Hydroform Small Rubber Press - Payer

Technologies Triform

Triform

1648-10BD

Max Pressure : 690 bar

Tray size : 16 X 48

41

Hydroform Large Blatter Press & Chiller - Avure

Technologies

Avure

QFC 1X2X800

Max Pressure : 800 bar

Tray size : 1m X 2m

52

Press Brake ~3500mm long

Cincinnati

175FM II

Max bed Length = 120"

Stroke Length = 10"

55

Sheet Metal Shear Machine

Cincinnati

No Model

Max shearing thickness =

3/16" (AL)

59

Stretch Form Press for Extrusions

Cyril Bath

91

Wheeling Press - English Wheel

IMPERIAL

35

97

Hydraulic Press - Small

Pacific

Pressformer II

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100 T press

35

F/P Insp

F/P
Deburr
H
T

To Solutionising

Rawma

Insp

To DF
36

Qualifications
[Link]

Team Member
Name

J Govindaraj

Ramakrishna J

Bhaskarraju K

Shivanna T.C

Mallyya

Mallikarjuna K

[Link]

Murali T.N

Solomon R

10

Kamalakanan G

11

Shiva kumar J.K

12

Punith kumar K.N

13

Manjunath N

14

Mahendran R

15

[Link]

16

Venkatachalam

17

G.H. Appasab

18

[Link]

19

Ragavendra

20

[Link]

21

Ramakrishna.V

22

Manjunath S.R

23

Manju D.P

24

[Link]

25

Amit kumar sharma

26

[Link] kumar

27

Manohar lal

28

Radha krishnan

29

Gribas

30

Raj kumar

31

Chumman lal sahu

32

Trilochan

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P1

P2

P3

P4

Rubber Press
Brake Press
Check and
Rolling
Forming
forming
Straighten
PMR #10 PMR #11 PMR #10 PMR #11 PMR #10 PMR #11 PMR #10 PMR #11 PMR #10 PMR #11 PMR #10 PMR #11 PMR #10 PMR #11 PMR #10 PMR #11
Shearing

Routing

Nibbling

Deburring

37

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