Chapter 16

Sheet-Metal Forming Processes

 Sheet-Metal Parts

(a) (b)

Figure 16.1 Examples of sheet-metal parts. (a) Die-formed and cut stamped parts.
(b) Parts produced by spinning. Source: (a) Courtesy of Aphase II, Inc. (b)
Courtesy of Hialeah Metal Spinning, Inc.
 Shearing
• Shearing: mechanical cutting of materials without
the formation of chips or the use of turning or
melting.
• Shearing starts with the formation of cracks on both
top & bottom edges of wp (A, B, C, D).
• Shearing parameters:
1. Shape of & materials for punch and die.
2. Punching speed.
3. Lubrication
4. Clearance, c, between punch & die. As c inc, the
sheared edge becomes rougher, and the zone of
deformation becomes larger (F16.2)
 Shearing with a
Punch and Die

Punch force, F  0.7TLUTS 



Figure 16.2 (a) Schematic illustration of

shearing with a punch and die, indicating
some of the process variables.
Characteristic features of (b) a punched
hole and (c) the slug. (Note: The scales
of the two figures are different.)
 Slitting

Slitting (F16.6): blades follow either a straight line or

circular or curved path.
Two types of slitting equipment:
1. Driven type: powered blades.
2. Pull-through type: strip is pulled through idling blades

Figure 16.6 Slitting with rotary knives. This process is similar to opening cans.