Manufacturing Lecture

Manufacturing Processes I
ME 303
Chapter 20-4
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
SHEET METALWORKING
Cutting Operations
Bending Operations
Drawing
Other Sheet Metal Forming Operations
Dies and Presses for Sheet Metal Processes
Sheet Metal Operations Not Performed on
Presses
SHEET-METAL OPERATIONS NOT
PERFORMED ON PRESSES
A number of sheet-metal operations are not
performed on conventional stamping
presses. i.e:
(1) Stretch forming,
(2) Roll bending and forming,
(3) spinning, and
(4) high-energy-rate forming processes.
STRETCH FORMING
A sheet-metal deformation process in which
the sheet metal is intentionally stretched and
simultaneously bent in order to achieve
shape change.
The combination of stretching and bending
results in relatively little spring-back in the
part.
FIGURE 20.39 Stretch
forming: (1) start of
process; (2) form die is
pressed into the work with
force F
die
, causing it to be
stretched and bent over
the form. F = stretching
force.
Stretch-Forming Process
Figure 16.30 Schematic illustration of a stretch-forming process. Aluminum skins for
aircraft can be made by this method. Source: Courtesy of Cyril Bath Co.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
STRETCH FORMING
An estimate of the force required in stretch
forming can be obtained by:

F = LtY
f

where
F = stretching force, N(lb);
L = length of the sheet in the direction perpendicular
to stretching, mm (in);
t = instantaneous stock thickness, mm(in); and
Y
f
= flow stress of the work metal, MPa (lb/in2).
STRETCH FORMING
More complex contours are possible by
stretch forming,
there are limitations on how sharp the
curves in the sheet can be.
widely used in the aircraft and aerospace
industries to economically produce large
sheet-metal parts in the low quantities.
ROLL BENDING AND ROLL FORMING
Roll bending use rolls to form sheet metal.
large sheet-metal or plate-metal parts are
formed into curved sections by means of
rolls.
large storage tanks and pressure vessels,
structural shapes, railroad rails, and tubes.
Roll straightening: nonflat sheets (or other
crosssectional forms) are straightened by passing
them between a series of rolls.
ROLL BENDING
FIGURE 20.40: Roll bending.
ROLL BENDING AND ROLL FORMING
Roll forming (or contour roll forming): a continuous
bending process in which opposing rolls are used to
produce long sections of formed shapes from coil or
strip stock.
Several pairs of rolls are usually required to
progressively accomplish the bending.
Products: channels, gutters, metal siding sections,
pipes and tubing with seams, and various structural
sections.
roll forming involves bending rather than
compressing the work.
ROLL FORMING
FIGURE 20.41: Roll forming of a continuous channel section: (1) straight rolls, (2)
partial form, and (3) nal form.
Roll-Forming Process
Figure 16.26 (a) Schematic illustration of the roll-forming process. (b) Examples of
roll-formed cross-sections. Source: (b) Courtesy of Sharon Custom Metal Forming,
Inc.
SPINNING
Spinning is a metal-forming process in which an
axially symmetric part is gradually shaped over a
mandrel or form by means of a rounded tool or
roller.
The tool or roller applies a very localized pressure
to deform the work by axial and radial motions.
cups, cones, hemispheres, and tubes.
Three types of spinning operations:
conventional spinning,
shear spinning, and
tube spinning.
Conventional Spinning
FIGURE 20.42: Conventional spinning:
(1) setup at start of process;
(2) during spinning; and
(3) completion of process.
It is the basic spinning operation.
a sheet-metal disk is held against the end of a
rotating mandrel of the desired inside shape,
the tool or roller deforms the metal against the
mandrel.
Based on tool position is control:
manual spinning and
power spinning
o Power spinning apply higher forces, resulting in faster cycle
times and greater work size capacity.
o It also achieves better process control than manual spinning.
The thickness of the metal more or less remains
unchanged
The diameter of the disk must be somewhat larger
than the diameter of the resulting part.
The starting diameter can be figured by assuming
constant volume, before and after spinning.
Applications:
production of conical and curved shapes in low
quantities. (Very large diameter partsup to 5m
or morecan be made)
Shear Spinning (flow turning,
shear forming, and spin forging)
The part is formed over the mandrel by a shear
deformation process
the outside diameter remains constant and the
wall thickness is reduced.
This shear straining (and consequent thinning of
the metal) distinguishes this process from the
bending action in conventional spinning.
The process has been applied in the aerospace
industry to form large parts such as rocket nose
cones.

FIGURE 20.43
Shear spinning:
(1) setup and
(2) completion of process.
Figure 16.42 (a) Schematic illustration of the conventional spinning process. (b) Types of
parts conventionally spun. All parts are axisymmetric.
After Materials and Processes in Manufacturing, by E. Paul DeGarmo, J.T. Black,
and Ronald A. Kohser, Prentice Hall of India, 2001.
2-stages in the spinning a metal
reflector.(Courtesy of Spincroft, Inc., New
Berlin,WI )
For the simple conical shape in our figure, the
resulting thickness of the spun wall can be readily
determined by the relationship:
t
f
= t sin
where t
f
= the final thickness of the wall after
spinning, t = the starting thickness of the disk, and
= the mandrel angle (actually the half angle).
Thinning is sometimes quantified by the spinning
reduction r:

There are limits to the amount of thinning that the
metal will endure in a spinning operation before
fracture occurs.
The maximum reduction correlates well with
reduction of area in a tension test.

Tube Spinning
used to reduce the wall thickness and increase
the length of a tube.
a roller is applied to the work over a cylindrical
mandrel.
It is similar to shear spinning except that the
starting workpiece is a tube rather than a flat disk.
The operation can be performed
1. applying the roller externally and using a cylindrical
mandrel on the inside of the tube, or
2. applying the roller internally and using a die that
surround the tube.
3. It is also possible to form profiles in the walls of the
cylinder.

Tube Spinning
FIGURE 20.44 Tube spinning: (a) external; (b) internal; and (c) proling.
Spinning reduction for a tube-spinning operation is similar to shear
spinning:
Shear-Spinning and Tube-Spinning
Figure 16.43 (a) Schematic illustration of the shear-spinning process for making conical
parts. The mandrel can be shaped so that curvilinear parts can be spun. (b) and (c) Schematic
illustrations of the tube-spinning process
Cost of Conventional Spinning Versus Cost of Deep Drawing
Figure 16.57 Cost comparison for manufacturing a round sheet-metal container either by
conventional spinning or by deep drawing. Note that for small quantities, spinning is more
economical.
HIGH-ENERGY-RATE FORMING
(HERF)
Processes developed to form metals using large
amounts of energy applied in a very short time.
They include:
explosive forming,
electrohydraulic forming, and
electromagnetic forming.

EXPLOSIVE FORMING
It involves the use of an explosive
charge to form sheet (or plate) metal
into a die cavity.
The workpart is clamped and sealed
over the die, and a vacuum is
created in the cavity beneath.
The apparatus is placed in a large
vessel of water.
An explosive charge is placed in the
water at a certain distance above the
work.
Detonation of the charge results in a
shock wave whose energy cause
rapid forming of the part into the
cavity.
It is reserved for large parts, typical
of the aerospace industry.

EXPLOSIVE FORMING
FIGURE 20.45 Explosive forming: (1) setup, (2) explosive
is detonated, and (3) shock wave forms part and plume
escapes water surface.
Explosive Forming
Figure 16.45 (a) Schematic illustration of the explosive forming process. (b)
Illustration of the confined method of the explosive bulging of tubes.
ELECTROHYDRAULIC FORMING
(electric discharge forming)

A shock wave is generated to deform the work
into a die cavity by the discharge of electrical
energy between two electrodes submerged in a
transmission fluid (water).
Electrical energy is accumulated in large
capacitors and then released to the electrodes.
smaller amounts of energy are released which
limits electrohydraulic forming to much smaller
part sizes.

ELECTROHYDRAULIC FORMING
(electric discharge forming)
FIGURE 20.46 Electrohydraulic forming setup.
ELECTROMAGNETIC FORMING (
magnetic pulse forming)

It is a process in which sheet metal is deformed
by the mechanical force of an electromagnetic
field induced in the workpart by an energized
coil.
The coil, energized by a capacitor, produces a
magnetic field which generates eddy currents
in the work that produce their own magnetic
field.
The induced field opposes the primary field,
producing a mechanical force that deforms the
part into the surrounding cavity.
It is the most widely used HERF process.
It is typically used to form tubular parts.

ELECTROMAGNETIC FORMING (
magnetic pulse forming)
FIGURE 20.47 Electromagnetic forming: (1) setup in which coil is
inserted into tubular workpart surrounded by die; (2) formed part.
Magnetic-Pulse Forming Process
Figure 16.46 (a) Schematic illustration of the magnetic-pulse forming process used to form a tube
over a plug. (b) Aluminum tube collapsed over a hexagonal plug by the magnetic-pulse forming
process.
BENDING OF TUBE STOCK
Bending of tube stock is more difficult than
sheet stock
A tube tends to collapse and fold when
attempts are made to bend it.
Special flexible mandrels are usually inserted
into the tube prior to bending to support the
walls during the operation.

FIGURE 20.48 Dimensions and
terms for a bent tube: D = outside
diameter of tube, R = bend radius,
t = wall thickness.
When the tube is bent,
the wall on the inside of the bend is in
compression, and
the wall at the outside is in tension.
These stress conditions cause
thinning and elongation of the outer wall and
thickening and shortening of the inner wall.
As a result, there is a tendency for the inner
and outer walls to be forced toward each other
to cause the cross section of the tube to flatten.
the minimum bend radius R that the tube can
be bent is
about 1.5 times the diameter D when a
mandrel is used and
3.0 times D when no mandrel is used.
The exact value depends on the wall factor
WF, which is D to t ratio.
Higher values of WF increase the minimum
bend radius; (i.e. tube bending is more difficult
for thin walls).
Ductility of material is also important in the
process.
Several methods to bend tubes:
Stretch bending
Draw bending
Compression bending
Roll bending
STRETCH BENDING
It is accomplished by pulling and bending the tube around
a fixed form block.
FIGURE 20.49 (a) stretch bending
DRAW BENDING
It is performed by clamping the tube against a form block,
and then pulling the tube through the bend by rotating the
block. A pressure bar is used to support the work as it is
being bent.

FIGURE 20.49 (b) draw bending
COMPRESSION BENDING
A wiper shoe is used to wrap the tube around the contour
of a fixed form block.

FIGURE 20.49 (c) compression bending
Methods of Bending Tubes
Figure 16.27 Methods of bending tubes. Internal mandrels or filling of tubes with particulate
materials such as sand are often necessary to prevent collapse of the tubes during bending. Tubes
also can be bent by a technique consisting if a stiff, helical tension spring slipped over the tube.
The clearance between the OD of the tube and the ID of the spring is small, thus the tube cannot
kick and the bend is uniform.
ROLL BENDING
Generally associated with the forming of sheet stock, is
also used for bending tubes and other cross sections.

FIGURE 20.40: roll bending

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Manufacturing Processes I

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