sheet metal forming processes manufacturing processes

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Sheet Metal Sheet Metal Forming Forming Processes Processes Manufacturing Manufacturing Processes Processes

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Page 1: Sheet Metal Forming Processes Manufacturing Processes

Sheet Metal Forming Sheet Metal Forming ProcessesProcesses

Manufacturing Manufacturing ProcessesProcesses

Page 2: Sheet Metal Forming Processes Manufacturing Processes

OutlineOutline

IntroductionIntroduction

ShearingShearing

BlankingBlanking

BendingBending

Deep DrawingDeep Drawing

Stamping DiesStamping Dies

Progressive DiesProgressive Dies

Transfer DiesTransfer Dies

SpinningSpinning

Page 3: Sheet Metal Forming Processes Manufacturing Processes

Sheet Metal WorkingSheet Metal Working

Products:Products:

automotive fendersautomotive fenders

washerswashers

stamped partsstamped parts

channelschannels

Page 4: Sheet Metal Forming Processes Manufacturing Processes

Examples of Stamped Examples of Stamped PartsParts

Page 5: Sheet Metal Forming Processes Manufacturing Processes

Examples of Stamped Examples of Stamped PartsParts

Page 6: Sheet Metal Forming Processes Manufacturing Processes

Examples of Stamped Examples of Stamped PartsParts

This part was made from several stamped parts plus a nut, which were stamped again to seal them

together

Page 7: Sheet Metal Forming Processes Manufacturing Processes

Examples of Stamped Examples of Stamped PartsParts

This part was made from a sheet that was stamped, bent, and welded into a tube, plus a separate

stamped end piece

Page 8: Sheet Metal Forming Processes Manufacturing Processes

Examples of Stamped Examples of Stamped PartsParts

Page 9: Sheet Metal Forming Processes Manufacturing Processes

ShearingShearing

A sheet-metal cutting operation along A sheet-metal cutting operation along a straight line between two cutting a straight line between two cutting edgesedges

Page 10: Sheet Metal Forming Processes Manufacturing Processes

Shearing of Metal Shearing of Metal Between Cutting EdgesBetween Cutting Edges

Page 11: Sheet Metal Forming Processes Manufacturing Processes

Shearing of Metal Shearing of Metal Between Cutting EdgesBetween Cutting Edges

1/3 of material is cut and 2/3 of material fractures

Page 12: Sheet Metal Forming Processes Manufacturing Processes

BlankingBlanking

Involves cutting the sheet metal along Involves cutting the sheet metal along a closed outlinea closed outline

Page 13: Sheet Metal Forming Processes Manufacturing Processes

Piercing and BlankingPiercing and Blanking

Shearing operations in which the Shearing operations in which the shear blades are closed, curved shear blades are closed, curved lines along the edges of the punch lines along the edges of the punch and dieand die

In blanking, the piece punched out is In blanking, the piece punched out is the workpiece; in piercing, the the workpiece; in piercing, the remaining strip is the workpieceremaining strip is the workpiece

Page 14: Sheet Metal Forming Processes Manufacturing Processes

Punch and DiePunch and Die

Page 15: Sheet Metal Forming Processes Manufacturing Processes

BendingBending

Page 16: Sheet Metal Forming Processes Manufacturing Processes

BendingBending

Page 17: Sheet Metal Forming Processes Manufacturing Processes

Bending SpringbackBending Springback

Page 18: Sheet Metal Forming Processes Manufacturing Processes

Deep DrawingDeep Drawing

A sheet metal forming operation used A sheet metal forming operation used to make hollow-shaped partsto make hollow-shaped parts

Page 19: Sheet Metal Forming Processes Manufacturing Processes

Deep DrawingDeep Drawing

Page 20: Sheet Metal Forming Processes Manufacturing Processes

RedrawingRedrawing

Additional drawing steps (redrawing) Additional drawing steps (redrawing) may be required if the shape may be required if the shape change of the material is too severechange of the material is too severe

Page 21: Sheet Metal Forming Processes Manufacturing Processes

Example of a Drawn Example of a Drawn PartPart

Page 22: Sheet Metal Forming Processes Manufacturing Processes

Example of a Deep Example of a Deep Drawing PressDrawing Press

Page 23: Sheet Metal Forming Processes Manufacturing Processes

Stamping DieStamping Die

Page 24: Sheet Metal Forming Processes Manufacturing Processes

Stamping DieStamping Die

Page 25: Sheet Metal Forming Processes Manufacturing Processes

Progressive DieProgressive Die

Performs multiple operations at Performs multiple operations at different stations with every press different stations with every press strokestroke

Page 26: Sheet Metal Forming Processes Manufacturing Processes

Progressive DieProgressive Die

Page 27: Sheet Metal Forming Processes Manufacturing Processes

Example of Progressively Example of Progressively Stamped PartsStamped Parts

This sheet has been stamped by a progressive die, showing the series of operations from right to left

Page 28: Sheet Metal Forming Processes Manufacturing Processes

Progressive DieProgressive Die

Page 29: Sheet Metal Forming Processes Manufacturing Processes

Progressive DieProgressive Die

Page 30: Sheet Metal Forming Processes Manufacturing Processes

Progressive DieProgressive Die

Page 31: Sheet Metal Forming Processes Manufacturing Processes

Progressive DieProgressive Die

Page 32: Sheet Metal Forming Processes Manufacturing Processes

Progressive DieProgressive Die

Page 33: Sheet Metal Forming Processes Manufacturing Processes

Progressive DieProgressive Die

Page 34: Sheet Metal Forming Processes Manufacturing Processes

Examples of Stamping Examples of Stamping MachinesMachines

Page 35: Sheet Metal Forming Processes Manufacturing Processes

Progressive DieProgressive Diein Stamping Pressin Stamping Press

Page 36: Sheet Metal Forming Processes Manufacturing Processes

Progressive DieProgressive Die

Page 37: Sheet Metal Forming Processes Manufacturing Processes

Material CoilsMaterial Coils

Page 38: Sheet Metal Forming Processes Manufacturing Processes

Material FeedMaterial Feed

Page 39: Sheet Metal Forming Processes Manufacturing Processes

Material FeedMaterial Feed

Page 40: Sheet Metal Forming Processes Manufacturing Processes

Transfer LineTransfer Line

Page 41: Sheet Metal Forming Processes Manufacturing Processes

Transfer LineTransfer Line

Page 42: Sheet Metal Forming Processes Manufacturing Processes

Transfer LineTransfer Line

Page 43: Sheet Metal Forming Processes Manufacturing Processes

Transfer LineTransfer Line

Page 44: Sheet Metal Forming Processes Manufacturing Processes

Transfer PressTransfer Press

Page 45: Sheet Metal Forming Processes Manufacturing Processes

Transfer PressTransfer Press

Page 46: Sheet Metal Forming Processes Manufacturing Processes

Transfer DieTransfer Die

Page 47: Sheet Metal Forming Processes Manufacturing Processes

SpinningSpinning

Uses a spinning mandrel and a roller Uses a spinning mandrel and a roller to form sheet metal into a radially to form sheet metal into a radially symmetrical partsymmetrical part

Page 48: Sheet Metal Forming Processes Manufacturing Processes

SpinningSpinning

Courtesy Koch Metal Spinning

Page 49: Sheet Metal Forming Processes Manufacturing Processes

Tube SpinningTube Spinning

Uses a spinning mandrel and a roller Uses a spinning mandrel and a roller to reduce the wall thickness and to reduce the wall thickness and increase the length of a tubeincrease the length of a tube

Page 50: Sheet Metal Forming Processes Manufacturing Processes

SummarySummary

Blanking, bending, and deep Blanking, bending, and deep drawing are capable of drawing are capable of producing an immense variety producing an immense variety of thin metal partsof thin metal parts

Progressive dies can produce Progressive dies can produce parts at high production rates parts at high production rates by performing multiple by performing multiple operations simultaneouslyoperations simultaneously

Page 51: Sheet Metal Forming Processes Manufacturing Processes