TODAY’S LECTURE CONTENTS

 Sheet Metalworking
 Cutting Operations

 Bending Operations

 Drawing

 Presses

 Roll bending and forming

SHEET METALFORMING
METAL FORMING OPERATIONS
 Metal forming includes a large group of manufacturing processes
in which plastic deformation is used to change the shape of
metal work pieces.
 Deformation results from the use of a tool, usually called a die in
metal forming , which applies stresses that exceed the yield
strength of the metal. The metal therefore deforms to take a shape
determined by the geometry of the die.
 However, some forming processes stretch the metal, while others
bend the metal, and still others apply shear stresses to the metal.
METAL FORMING OPERATIONS
 To be successfully formed, a Metal must possess certain properties.
Desirable properties include low yield strength and high ductility.
These properties are affected by temperature. Ductility is increased
and yield strength is reduced when work temperature is raised
 The effect of temperature gives rise to distinctions between cold
working, warm working, and hot working.
 Strain rate and friction are additional factors that affect performance
in metal forming.
METAL FORMING OPERATIONS
Metal forming processes can be classified into two basic categories:
➢ Bulk deformation processes

➢ Sheet Metalworking
SHEET METALWORKING
SHEET METALWORKING
 Sheet metalworking processes are forming and cutting operations
performed on metal sheets, strips, and coils.
 The surface area-to-volume ratio of the starting metal is high;
thus, this ratio is a useful means to distinguish bulk deformation from
sheet metal processes.
 Press working is the term often applied to sheet metal operations
because the machines used to perform these operations are
presses (presses of various types are also used in other manufacturing
processes).
 A part produced in a sheet metal operation is often called a stamping.
 Sheet metal operations are always performed as cold working
processes and are usually accomplished using a set of tools called a
punch and die. The punch is the positive portion and the die is the
negative portion of the tool set.
SHEET METALWORKING
The basic sheet operations are as follows
 Bending

 Drawing

 Shearing

 Miscellaneous Processes (that don not use punch and die tooling
i.e. Stretch forming ,Roll bending spinning and bending of tube
stock )
CUTTING OPERATIONS
CUTTING OPERATIONS (SHEARING )
 This process seems somewhat out-of-place in a list of deformation
processes, because it involves cutting rather than forming. A
shearing operation cuts the work using a punch and die, as in
Figure.
 It is not a forming process and very common operation in sheet
metal working.
CUTTING OPERATIONS (SHEARING )

(1) as punch first contacts sheet, and (2) after cutting. Force and relative motion in these
operations are indicated by F and v.
BENDING OPERATIONS
BENDING OPERATIONS
 Bending involves straining of a metal sheet or plate to take an
angle along a (usually) straight axis.
DRAWING
DRAWING
 In sheet metalworking, drawing refers to the forming of a flat
metal sheet into a hollow or concave shape, such as a cup, by
stretching the metal. A blank holder is used to hold down the blank
while the punch pushes into the sheet metal. To distinguish this
operation from bar and wire drawing, the terms cup drawing or
deep drawing are often used.
DRAWING
PRESSES
PRESSES
Types of presses for sheet metal working can be classified by one or a
combination of characteristics, such as source of power, number of
slides, type of frame and construction, type of drive, and intended
applications.
PRESSES
 Manual Presses: These are either hand or foot operated through levers,
screws or gears. A common press of this type is the arbor press used for
assembly operations.
 Mechanical presses: These presses utilize flywheel energy which is
transferred to the work piece by gears, cranks, eccentrics, or levers.
 Hydraulic Presses: These presses provide working force through the
application of fluid pressure on a piston by means of pumps, valves,
intensifiers, and accumulators. These presses have better performance
and reliability than mechanical presses.
 Pneumatic Presses: These presses utilize air cylinders to exert the
required force. These are generally smaller in size and capacity than
hydraulic or mechanical presses, and therefore find use for light duty
operations only.
PRESSES
 Factors affecting the selection of a press are size, force, energy and
speed requirements.
 Mechanical presses are very widely used for blanking, forming and
drawing operations required to be done on sheet metal. For certain
operations which require very high force, for example, hydraulic
presses are more advantageous
PRESSES
Characteristic Mechanical Presses Hydraulic Presses
Dose not depend upon slide
Force Depends upon slide position.
position. Relatively constant.
Long strokes, even as much
Stroke length Short strokes
as 3 m.
Slow. Rapid advance and
High. Highest at mid-stroke.
Slide speed retraction. Variable speeds
Can be variable
uniform throughout stroke.
Capacity About 50 MN (maximum) About 500 MN, or even more.
Full stroke generally required Adjustable, slide reversal
Control
before reversel. possible from any position.
ROLL BENDING &
FORMING
ROLL BENDING & FORMING
 Roll bending is similar to bending, as the material is formed by
applying a force. The metal sheet is not cut and no material is
removed. For this reason, roll bending of metal sheets is one of
the chip less sheet metal forming methods.
 Roll bending is used if a metal sheet panel is to be given a larger,
smooth radius, which we can only produce in our press brakes with
step bending.
ROLL BENDING & FORMING
 Before a metal sheet panel can be bent, the minimum bending
radius must be determined. This value represents the limit, at
which the material can still be bent without defects.
 If the radius used is less than the minimum bending radius the
metal can tear at the edges or can spall.Torn workpieces can then
no longer be used. This radius differs from material to material.
ROLL BENDING & FORMING
ROLL BENDING & FORMING
 In the case of steel sheet or plate, the sheet thickness is multiplied by
a factor of 1 to 3.
 In the case of aluminum this factor is 0.8 to 1 and is significantly
smaller compared to steel sheet.
 If a steel sheet or plate that is 10 mm thick can be bent with a
minimum radius between 10 and 30 mm. The closer the lower limit
of this range is approached during roll bending, the greater the risk
of fracture

 www.machinemfg.com/3-roll-bending-machine-working-principle-
rolling-process/
ROLL BENDING & FORMING
END