SHEET METAL

PRESSING PROCESSES

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Pressing process
Definition of pressing process
It is the process by which the sheet metal is pressed
(pierced, blanked, bent, formed) to get the required shape
and size

General pressed part application

WHEEL RIMS PETROL TANKS

2 WHEELER FRAME

OUTER BODY OF APPLIANCES SILENCERS SWING ARM

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Why Sheet metal & Pressing process
 Ease of manufacture & less
process complexity
 Thin sections can be
produced as low as 0.2mm
 High productivity.
 Cost effective.
 Can be easily fabricated by
using joining technology.
 Superior strength and good
aesthetics if painted / plated/

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Types of Pressing operation
Cutting operation
(Normally a chip less operation)

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[Link] [Link] blanking
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[Link] off [Link]
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Types of Pressing operation

Forming operation
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[Link] drawing [Link]
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 CUTTING OPERATIONS

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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 SLITTING or SHEARING blades

SHEARING

SLITTING

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Shearing
 Normal cutting Blanking
(Shearing)

Chips

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Blanking
• Blanking is a process producing flat stampings.
• The entire periphery is cut and the cut-out by a single
punch & die
• The cut out piece is a blank or stamping.
• The tool used is called as blanking tool
Blanking
punch
Punch

Sheet
Scrap

Die
Output
product

Blanking
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Piercing
• Piercing is a process of making hole in the stamping.
• Entire periphery is cut-out by a single punch & die
• The cutout piece (Slug) is a waste. The tool used is called
piercing tool
Process - 1 Process - 2
Piercing Piercing operation Blanking operation
punch
Blanking
punch
Input
raw material

Scrap
Required
Scrap part

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Notching
This operation removes a small amount of material from the
edges of the strip or a blank.
Notching serves to shape
the outer contours of the
work piece in a progressive
tool or to remove excess metal
before a drawing or forming
operation in a progressive tool

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Notching examples

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Trimming
 It is a shearing operation which
removes the excess unwanted material
from a drawn part.

Why Trimming operation ?

 To remove the excess

material on a drawn part to
achieve desired shape and
clean finish part.

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Trimming

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Parting off
• The parting off operation separates the work material
along a straight line in a double line cut.
• The piece removed by the punch is scrap.

Why Parting off operation ?

• Material saving at the sides

compared to Blanking
operation.

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Parting off

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Cutting off
 A cut off operation separates
the work material in a single
cut line.
 No scrap is produced in cutting
off operation. The process of
cutting off is similar to shearing
in a shearing machine.
 Cutoff lines may be straight,
curved, or jagged.
Why cutting off operation ?

 No material scrap in Cut-

off operation.
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Cutting off

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Cutting off

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Cutting off

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Typical parting off die

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Comparison
Cutting off Parting off

Slug
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Typical cutting off die

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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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Perforating

Press used for full width

perforation of sheets

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Nibbling
Punching a series of small overlapping slits or holes along a
path to cutout a larger contoured shape.
This eliminates the need for a custom punch and die but will
require secondary operations to improve the accuracy and
finish of the feature

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Dinking

 Dinking is done to create holes on soft material using a

hollow punch against a soft support

Dinking
Punch

Sheet metal

Bottom support
(Soft material)

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Dinking
 It can be used to cut-out parts of various shapes
from soft materials

Dinking tool

Material to be cut

Soft support

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Dinking application
Shaving
 Shaving finishes a previously cut edge by shearing off a
small amount from the previovs cut edge.

Why Shaving operation ?

 Shaving increases accuracy and

finish (smoothness).

 Alternate to fine blanking process

 Carried out in 2 to 3 stages for higher

accuracy and surface finish

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Shaving
From Die-roll side (in progressive tools)

Before After

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Shaving
From Burr side (In Stage tools)

(a)
Before
Fracture
cross-section Burr

Cut band

Radius

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 Nest/locator

Die

Shaved part

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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 undesirable for
parts having like gear teeth, cam
faces, drive chains etc.

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Fine Blanking

Hence fine blanking is preferred for these

type of parts. Recommended cutting
clearance for fine blanking is 0.5% of
sheet thickness

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What is Fine Blanking?
 In Fine blanking, a ‘V’-ring(2)
compresses the metal while
the punch(3) shears the metal
against a counter-pressure (4)

 The result is an edge that is

entirely smooth

 Fine blanking can produce

hole diameter as little as 40 -
50% of material thickness

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

 No scrap is generated in
this process

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Louvering

Usually done to create

openings for ventilation

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Broaching
 A cutting operation carried-out on presses to create keys
/ key ways or splines using Broaches.

Broached parts

Broaches
Unlike other press operations broaching creates chips
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Broaching
Types of Broaching machines

Vertical – Multi head

Vertical Horizontal

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Broaching done on Arbor Press

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Broaching

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Broaching

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 FORMING OPERATIONS

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Bending
 It is the deforming of metal in
a straight line 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

Bending
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 16) Forming
 It is similar to bending
except the line of bend
is along the curved axis
instead of a straight line.

 The metal flow is not

uniform as in bending
and it depends on the
shape of the component.

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Flanging
 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 edge of the
part
Fuel tank inner
 Also facilitate location/guide
for next assembly parts

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Embossing
 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 part

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Embossing

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Flaring or Lugging

 The process of flaring is forming

an outward flange on parts
using a flaring tool
 It is similar to bulging operation.

Why Flaring operation ?

 It is done to facilitate assembly

or joining operation.

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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.

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Collar Drawing

C draw.
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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
Curling
improves the appearance of the part
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.

Stage 1. tilting Stage 2. Stage [Link] Stage 3. finish

Curling
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 WIRE

Wire inside the curl

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Bulging
 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 to facilitate assembly or
joining operation.

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Swaging or Necking

 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 to facilitate assembly or joining operation.

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Swaging or Necking

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Seaming
 Seaming joins the edges of
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 join edges

of a cylindrical containers
from a single sheet.

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Hemming

 Hemming bends and folds the

edge of sheet metal back upon
itself.

Why Hemming operation ?

 It increases stiffness, improves

appearance, and removes any sharp edges.

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Hemming

Hemming with re-inforcement

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Planishing
 Usually a blanked part is slightly cup
shaped
 It is used to straighten the blanked
component.
 Very fine serration points penetrate
on top and bottom of the part.

Why Planishing operation ?

 Releases stress and improves the
straightness of the component

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Planishing

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Extrusion
 A process used to manufacture pipes or profiles out of
steel or aluminum.

 Performed either in hot or cold condition.

 Collar draw operation often combined with additional

profiles and extra lengths done on thick sheets by press
operation also called Extrusion.

Extrusion
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Extrusion
A compression forming process in which the work metal
is forced to flow through a die opening to produce a
desired cross-sectional shape.

Continuous extrusion

Forward extrusion

Backward extrusion

Combined extrusion

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Extrusion

Extrusion

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Coining

 To create different
impressions on the faces of the
part

Why Coining operation ?

 The thickness of the part

varies

Coining
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Rolling
 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 and part cost
Wheel
 Process simplicity rim

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• Diameter of roll is gradually increasing

• Axis of all rolls must be in straight line

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 Part
Observe the component below the machine
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Drawing
 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.

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Drawing

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Two methods for drawing operations

 Simple Drawing

 Deep drawing
Simple Drawing

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Deep Drawing
 Deep drawing is a process of cold forming a flat precut
blank into a hollow vessel.
Various forms can be produced.

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31 Ironing

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Exercise

Name the pressing operation

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1. Identify the operations performed

3
2

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 2
Pin planishing
3
Notching

4 Bending

1 Piercing

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2. Identify the operations performed
2
1 3

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 Flanging 2 Trimming
Embossing 3
1

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3. Identify the operations performed

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Flanging 1

2
Forming

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