V.R.S.

COLLEGE OF ENGINEERING & TECHNOLOGY,

(Reaccredited by NAAC and an ISO 9001:2008 Recertified Institution)
ARASUR - 607107, VILLUPURAM DISTRICT.
DEPARTMENT OF MECHANICAL ENGINEERING
Subject Code/Name : ME 3393/MANUFACTURING PROCESSES
Regulation : R-2021
Year/Sec : SECOND YEAR
Semester : THIRD SEMESTER

UNIT – 4
SHEET METAL PROCESSES

Sheet metal characteristics – Typical shearing, bending and drawing operations – Stretch forming
operations– Formability of sheet metal – Test methods –special forming processes – Working
principle and applications – Hydro forming – Rubber pad forming – Metal spinning – Introduction
of Explosive forming, magnetic pulse forming, peen forming, Super plastic forming – Micro
forming – Incremental forming.

Contents
Sheet metal characteristics ................................................................................................................................. 5
Typical Shearing, Bending and Drawing Operations ........................................................................................ 6
Stretch Forming Operation ................................................................................................................................ 9
Formability of Sheet Metal .............................................................................................................................. 11
Testing Methods .............................................................................................................................................. 12
Special Forming Process Working Principle and Applications ....................................................................... 13
Hydro Forming ................................................................................................................................................ 13
Rubber Pad Forming ........................................................................................................................................ 15
Metal Spinning Process ................................................................................................................................... 17
Introduction Explosive Forming ...................................................................................................................... 19
Magnetic Pulse Forming .................................................................................................................................. 21
Peen Forming Process...................................................................................................................................... 23
Super Plastic Forming...................................................................................................................................... 23
Micro Forming ................................................................................................................................................. 26
Incremental Forming ....................................................................................................................................... 27
Blanking and Punching .................................................................................................................................... 27
Compound and Progressive Die ...................................................................................................................... 29

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 PART-A (2 MARKS)
1. Define spring back. How is it recovered? (April/May -10, 12, 13;Nov/Dec -13)
What is meant by spring back in sheet metal forming? (Nov/Dec - 2020)
Spring back is defined as the movement of the metal to resume its original position causing a decrease in
bend angle after the applied force is withdrawn. It is recovered by techniques such as over-bending.
2. Define peen forming. What are their applications?(April/May- 2010; April-2008)
Peen forming is a process of well-established surface cleaning. In this process, a stream of metal shots is
blasted against the surface of the blank to be made into the required shape.
Application
➢ This process is used for producing specific portions on crankshafts, connecting rods and gears
➢ It is used for producing honeycomb panels like aircraft wings and large tubular shapes.
3. List some of the sheet metal operations. (Apr/May-2023)
Sheet metal operations are a set of processes that involve using forces to change the shape of a sheet metal
into the desired form or shape needed for a manufacturing process. The external force used alters only the
external features of the sheet. However, parameters of the one type of sheet metal such as length and thickness
remain the same. The malleability of the sheet metal further allows it to undergo various shaping processes
4. What is ironing, applied to sheet metal work? (Nov/Dec.2011)
The process of reducing wall thickness and lengthening of the cup is known as ironing. Annealed cups can
be reduced to 50% of wall thickness.
Volume before ironing = Volume after ironing
𝜋 d t h = 𝜋 d t1 h1
Where, d = diameter of the cup
t = blank thickness
t1 = reduced thickness or die clearance
h = height of the cup
h1 = increased height
5. What are the advantages of Rubber Pad Forming process? (Nov/Dec-2011), (Apr/May-2023)
➢ This process is more economical.
➢ Many required shapes can be formed in one rubber pad itself.
➢ There is no need of lubricants.
➢ Tool setting time is less.
6. What are the advantages of hydro forming process.(May-2012)
❖ Complicated contours can also be made.
❖ Sharp corners are also possible.
❖ All types of sheet metals can be handled.
7. What are the limitations of explosive forming? (Nov-2012)
1. Highly trained operators are needed.
2. Noisy operation.
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8. What is the lancing operation? (Nov-2012)
It is an operation in which cutting the sheet metal through a small length and bending this small cut portion
downwards.
9. What is sheet metal work? (April/May - 2013)
The working of metal thickness ranging from 3mm to 5mm into various forms is known as sheet metal
work.
10. List the various major shearing operations in sheet metal.
✓ Shearing
✓ Bending
✓ Drawing
✓ Squeezing
11. Define clearance. (Nov/Dec - 2008)
Clearance is the intentional space between the punch and die-cutting edges. Depending on the type of
cutting operation, the space between punch and die is provided known as clearance.
12. List out the applications of stretch-forming operations.
✓ Production of aircraft using fuselage parts.
✓ Production of contoured panels for truck trailers and bus bodies in automobile industry.
13. What are the formability test methods?
✓ Formability tests for bulk deformation.
✓ Formability test for elastic plastic deformation
✓ Simulative tests for forming operation
✓ Full scale forming tests.
14. Define punching operation. (May/June - 2005)
Punching is defined as making a hole in a given job. The principle operation of this process is planning
the heated job over a correct hole of the swage or die and forcing the punch into it by hammer.
15. What is super plastic forming operation? (Nov/Dec - 2007)
Super plasticity of metals is defined by very high tensile elongations, ranging from two hundred to several
thousand percent. Super plasticity is the ability of certain materials to undergo extreme elongation at the
proper temperature and strain rate.
16. Give the difference between piercing and blanking(Nov/Dec - 2019)
Piercing: it is the operation of producing a hole on the workpiece.
Blanking: it is the operation of cutting a flat shape from sheet metal.
17. How is hydro–forming similar to rubber forming (Nov/Dec - 2007)
In this forming method, a rubber diaphragm or seal is used for making perfect scaling between male and
female die
18. What are the types of special forming process? (Nov/Dec - 2008)
✓ Hydro forming
✓ Rubber pad forming
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 ✓ Metal spinning
✓ Explosive forming
✓ Magnetic pulse forming
✓ Peen forming
19. What is the effect of clearance in the punch and die for shearing sheet metal?(April/May -2019)
A small clearance, typically 10-20% of the material thickness, exists between the punch and die.
When the punch impacts the sheet, the metal in this clearance quickly bends and then fractures. The blank
which has been sheared from the stock now falls freely into the gap in the die.
20. Define limiting drawing ratio.(May/June - 2006)
The volume of material removed from the work per unit volume of wear. This ratio is called limiting drawing
ratio.
21. Define “embossing”
It is the process of producing required shapes on sheet metal blanks by means of punches and dies.
22. Write the shot notes on hydro forming.
Hydroforming is a specialized type of die-forming operation that uses a high pressure hydraulic fluid to press
room temperature working material into a die.
23. What is metal spinning process?(May/June - 2006)
The process of forming seamless metal parts from a circular sheet metal or from a tube length on a lathe is
called as spinning process. It can be used to produce symmetrical objects.
24. State the various methods of spinning.
✓ Manual spinning
✓ Power spinning
25. Name the various processes can be performed by explosive process.
Blanking, cutting, expanding, coining, embossing, flanging, power compacting, drawing and sizing operation
etc..
26. Mention the various types of simulative tests carried out for various cup forming.
✓ Erickson test
✓ Olsen test
✓ Shrift test
✓ Fukui test
27. What is stretching? (April/May - 2008)
Stretching stresses the work blank beyond its elastic limit by moving the form block towards the blank or
sheet metal.
28. State the methods of the stretch forming process.
✓ Form–block method
✓ Mating–die method
29. What is meant by seaming? (April/May - 2008)
The process of producing between the two edges of the different work metals is called as seaming.
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30. What is meant by the formability of sheet metal?( Nov/Dec - 2019, 2020)
✓ Formability is defined as the material is forced into a permanent change of shape.
✓ The formability of a material depends on several factors.
✓ An important factor of material like yield strength, strain hardening rate and ductility. These are
greatly temperature-dependent.
31. Mention the Advantages of super plastic forming. (Nov/Dec - 2008, 2013)
✓ It is a one step process
✓ Higher material elongation.
✓ Elimination of necessary joints
✓ Minimizes the amount of scarp
✓ Reduction of subsequent machining
32. What are the applications of forming a limit diagram?(Nov/Dec -2008)
✓ The new set of tools in easy, hard or impossible to work can be easily determined.
✓ Good materials used in forming operations are identified.
✓ Location of source of trouble is also easy from a reference pressing by the designer.
33. Name at least six common deep drawing defects. (Nov/Dec – 2021)
✓ Metal Fracture
✓ Wrinkles on the Top Edge
✓ Uneven Top Rim
✓ Fractures at the Bottom of the Cup
34. What are the factors influencing the bending operations? (Nov/Dec - 2021)
Spring back in sheet metal bending depends upon different variable parameters like sheet metal material,
sheet metal thickness, punch angle, punch height, punch radius, punch load, die opening, die lip radius, sheet
metal material grain direction, pre-bend strip condition etc.
PART-B (13 & 15 MARKS)

Sheet metal characteristics

1. List out the characteristics sheet metal forming process. (Nov/Dec -2008)
Roll forming:-Long parts with content complex cross section, good surface finish, high production rates,
and high tooling costs are produced.
Stretch forming:-Large parts with shallow contours suitable for low- quality production, high labor costs,
tooling and requirements costs depend on part size are produced.
Drawing:-Shallow or deep parts with relatively simple shape, high production rates, and high tooling and
equipment costs are produced.
Stamping:-It includes a veracity of operations, such as punching, blanking, and embossing bending,
hanging and coining, simple or complex shape are formed at high production rates, tooling and equipment
costs can be high, but labor cost is low.
Rubber forming: It includes drawing and embossing of simple or complex shapes, sheet surfaces protected
by rubber membranes, flexibility of operation, low tooling costs.
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 Spinning:-Small and large ax symmetric parts, good surface finish, low tooling cost , but labor cost can be
high unless operations are automated.
Super plastic forming:-Complex shapes, fine detail and close tolerance, forming times are long. Hence
production rate is low. So, parts are not suitable for high temperature use.
Peen forming:- Shallow contour on large sheets, flexibility of operation, equipment costs can be high,
process is also used for straightening parts.
Explosive forming:-Very large sheets with relatively complex shapes, although usually asymmetric, low
tooling costs, but high labor cost, suitable for low-quantity production, long cycle time are produced.
Magnetic pulse forming:-Shallow forming, bulging and embossing operations on relatively low strength
sheets, most suitable for tubular shapes, high production rates, require special tooling

Typical Shearing, Bending and Drawing Operations

2. Enumerate with neat sketches three phases in shearing. (April/May - 2010)
What is shear forming? Explain. (Nov/Dec – 2021)
The process of cutting a straight line across a strip, sheet or bar is known as the shearing process. This action
has three important basic stages.
1. Plastic deformation
2. Shear and
3. Fracture
Fig shows the four stages of the shearing process:
➢ Plastic deformation: When the blades begin to apply pressure, the workpiece undergoes elastic
deformation. As pressure increases the workpiece undergoes plastic deformation.
➢ Shear: The bladesbegins to penetrate either side which produces shear of workpiece along a vertical
line. Work hardening occurs in the centre.
➢ Fracture: Fracture lines originating from the point of each blade meet in the centre of the work piece
causing separation before the blades have fully penetrated.

3. What are various bending operations? Explain any four. (April/May - 2010)
Explain the bending operations with neat diagrams and mentions the applications. (Nov/Dec – 2019)
There are different types of bending operations as follows:
1. Angle bending
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 2. Roll bending
3. Roll forming and
4. Seaming
Angle bending
In this case, the metal is bent at an angle to each edges. It is denoted by “𝜭”.
If 𝜭<900 , it is called as single bending.
If 𝜭 =900, this is called as vertical or straight bending.
If 𝜭<900 but in two places on the same work, it is called as double bending.

Roll bending
If the metal is bent in the form of rolled edge at the edges of the work, it is called as roll bending.

Roll forming
If the edges are formed to a desired shape or any impression in the form of bend is made on the sheet
metal, it is called as roll forming operations.
Seaming
The process of providing lock between the two edges of the different work metal is called as seaming.
To perform this, the edge of sheet metal to be locked is bent in opposite direction to each other. Then
they are inserted with each other and pressed or tightened to make complete lock.
4. Explain about types of tube bending. (April/May – 2019)
The method of tube bending you use will vary depending upon factors such as the quality of the metal you’re
using, the planned function of the finished product and the resources you have at hand.
Press Bending

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 The easiest and most common type of tube bending, this process involves pressing a “bend die” against the
pipe to force it to conform to the shape of the bend. This is not a precision form of bending, because there
can be some deformation of the pipe due to a lack of internal support.
Rotary Draw Bending
A more precise type of bending is rotary draw bending.
This type of bending uses a rotary draw machine, which bends the metal through a series of die sets with a
consistent center line radius. Rotary draw benders allow for more specific jobs and are used to bend tube
and pipe for products like roll cages, hand rails and handles.
Roll Bending
Roll bending involves the use of a machine with three rollers, called a jig. It can be used to bend both sheet
metal and metal bars. It works by putting the bar into the jig and manually lowering and pressing the middle
roller against the bar. As the rollers are rotated, the bar moves along and force is applied to the bar as it
goes back and forth along the rollers until it reaches the desired shape. Roll bending can be good for circular
fabrications, such as wheel rims.
Mandrel Functions
A Mandrel is less a method of tube bending and more an aid to tube bending. As a piece of tube is bent, the
external wall of the tube necessarily thins. This comes with a tightening of the bend radius and an increased
chance of a flattened bend. To counter this, a device called a mandrel is sometimes put inside the tube at
the point of the bend. This offers support and increases the chance of getting the desired shape when
bending.
Wiper Dies
Mandrels help when the external wall thinning becomes a problem, but in extreme situations, like when a
thin tube needs a tight bend, a wiper die may be needed. The wiper is inserted into the grove between the
tube and the bending die to prevent a wrinkle defect due to uneven internal wall compression.
5. Describe with illustrative sketches, the following sheet metal operations: (May/June - 2012)
Bending edge of a sheet using wiping die
➢ Wiping die bending, also known as edge bending is performed by holding the sheet between a pad and
die then sliding the wiping flange across the face pushing and bending the sheet metal which protrudes
from the pad and die.
➢ The flange is driven by an upper shoe and the die is supported by a lower shoe.
➢ A spring between the pad and upper shoe grabs the metal before the flange hits it and holds the
workpiece down during the bending process.
➢ If the flange has a feature associated with it, other than just a straight bend then a stronger spring will
help prevent the metal from being pulled from the area between the die and pad.
➢ This will lead to less deformation when the piece comes out of the stamp

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 Roll bending (REFER Q.NO:2)
Stretch forming (REFER Q.NO:5)
Deep drawing
The process, which is used to draw the cup shaped parts from the metal, is called deep drawing.
The working principle of this process is that the metal blank is initially heated to a plastic state and placed
on the die or cavity.
Then the forces are given by using the punch, so the required shape of cup according to the shape of cavity
is produces. This process is continuous process for making smaller size cups.

Stretch Forming Operation

6. Explain the principle of stretch forming? Explain its types.(Nov/Dec-2009)
How curvatures are made on thin sheet metals? Explain the suitable process with neat sketch. (Nov/Dec
– 2013, 2019)
List out various Stretch forming methods. Explain any one. (Nov/Dec - 2020)
What is stretch forming? Explain the process with neat diagram. (Nov/Dec – 2021)
Stretching stresses the work blank beyond its elastic limit by moving a form block towards the blank or sheet
metal.
Methods of stretch forming:
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Stretch forming can be done in two methods
✓ Form – block method
✓ Mating die method
Form – block method
✓ In this method, the two ends of the blank or metal strip is tightly hold by an adjustable gripper.
✓ These grippers are fixed but adjustable.
✓ Then, the form block is moved towards the blank to make the required shape.
✓ In this case, the form – block is operated by hydraulic cylinder.
✓ When the form block moves towards the blank, the hydraulic fluid gets compressed and delivered
through the outlet valve.
✓ The movement of the form block always depends upon the hydraulic fluid pressure.
✓ The fluid is entered the cylinder when the form-block moves away from the blank after completing
stretching process.
✓ In a single stretching process, we can get no need of stage in stretching.
✓ Force exerted on the piston is calculated as
F=π/4 D2P
P=Hydraulic fluid pressure
D= diameter of the piston.

Mating – die method:

✓ In this method, the blank is tightly hold on movable grippers.
✓ The blank is placed between the lower and upper die.
✓ The lower die is kept stationary and the upper die is movable in which operated by hydraulic or
pneumatic cylinders.
✓ First, the movable grippers are moved towards the lower die on whichan elastic deformation takes
place.
✓ Next, the upper die is moved towards the blank.
✓ When the upper die touches the blank, only elastic changes takes place.

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 ✓ Due to continuous stretching of the blank by the upper die, plastic flow of sheet metal takes place
between lower and upper dies.
✓ When the upper die edge reaches the top surface of the blank the stretching process is completed.

Materials for die and form blocks

Wood, Masonite, zinc alloys, cast iron
Advantages:-
❖ No need of any heat – treatment before and after the stretching process.
❖ Tooling costs are low.
❖ Direct bending is required
❖ Plastic deformation is due to pure tension only.
❖ This method is more suitable for low volume production.
Disadvantages:-
❖ Maintenance cost of hydraulic cylinder is high.
❖ The process requires high quality form – blocks
❖ Blank thickness should be uniform throughout the length.
❖ Sudden changes in contour surface cannot be stretched.
Limitations:-
❖ Uneven thickness of blank cannot be stretched.
❖ Stretching of blank to the required shape of contour is limited.
Applications:-
❖ Production of aircraft wing & aircraft body.
❖ Production of contoured panels for truck in automobile industry.

Formability of Sheet Metal

Formability refers to the ability of sheet metal to be formed into a desired shape without necking or
cracking. Necking is localized thinning of the metal that is greater than the thinning of the surrounding metal.
Necking precedes cracking.
Sheet metal formability refers to the ability of a sheet metal material to be deformed into a desired

11
 shape without causing defects such as cracks, fractures, or excessive thinning. This property is crucial in
various industries, including automotive, aerospace, construction, and consumer goods, where sheet metal
components are commonly used.
The formability of sheet metal is influenced by several factors:
1. Material properties: The mechanical properties of the sheet metal material, such as yield strength,
tensile strength, ductility, and strain hardening, play a significant role in determining its formability.
Ductile materials with high elongation capabilities are generally more formable.
2. Thickness: Thinner sheets are usually more formable than thicker sheets. However, extremely thin
sheets may be more susceptible to wrinkling during forming processes.
3. Grain structure: The grain size and orientation in the sheet metal can affect its formability. Finer
grain structures typically exhibit better formability than coarser grain structures.
4. Strain rate: The rate at which the sheet metal is deformed can influence its formability. Some materials
exhibit different formability characteristics at different strain rates.
5. Temperature: The temperature at which the forming process is conducted can impact formability.
Elevated temperatures may increase the formability of certain materials by reducing their yield
strength.
6. Lubrication: The use of lubricants during forming processes can reduce friction and improve the
material's flow, thereby enhancing formability.

7. Anisotropy: Many sheet metals are anisotropic, meaning their mechanical properties vary with
orientation. Understanding the material's anisotropy is essential in predicting its formability in different
directions.
✓ To evaluate sheet metal formability, various tests are conducted, such as the Erichsen cupping test, the
Nakajima test, the deep-drawing test, and the Olsen cupping test.
✓ These tests help determine the limiting drawing ratio, the minimum bend radius, and other critical
parameters that define the material's formability.
✓ Manufacturers and engineers often consider the formability of sheet metal materials during the design phase
to ensure successful forming processes and the production of high-quality components.
✓ They may also use simulations and finite element analysis (FEA) to predict and optimize the formability of
sheet metal parts before actual production.

Testing Methods
7. Discuss different test requirements of the formability of sheet metal. (Nov/Dec- 2020)
➢ Formability is defined as the material is forced into a permanent change of shape.
➢ The formability of a material depends on several factors.
➢ An important factor of material like yield strength, strain hardening rate and ductility. These are greatly
temperature - dependent.
Formability of sheet metal can be evaluated by various tests like,
➢ Cup or Radial drawing,
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 ➢ Swift cup drawing test,
➢ Fukui's conical cup drawing test,
➢ Erichsan cupping test,
➢ Osu formability test,
➢ Hydraulic bulge test,
➢ Duncan Friction Test.
These tests are widely used to evaluate of formability for different sheet metals.
Formability is defined as ability to undergo plastic deformation without taking failure in forming
operation. These operations contains like deep drawing, cup drawing, bending and involves tensile
deformation. Common failures of deep drawing processes are wrinkling, Tearing, necking
Formability of sheet metal can be evaluated by various tests like swift cup drawing test, Fukui’s conical
cup drawing test, erichsan cupping test, osu Formability Test, Hydraulic Bulge Test, Duncan Friction Test.
These tests are widely used to evaluate of formability for different sheet metals. Different types of
testing methods of formability of sheet metal
Cup or Radial Drawing:
❖ Cup or radial drawing test uses a circular blank from the metal to be tested.
❖ It is an inserted in a die, and the severity of the drawing is able to withstand without deformation is
called the drawing ratio, is noted.
❖ The drawing ratio is the ratio of the cup diameter to the blank diameter.
Where Rd = drawing ratio
D = blank diameter
d = punch diameter
➢ Deep drawing is a process to obtain objects like cup shaped, pressure vessels, gas cylinders etc.
➢ In deep drawing process Sheet metal placed on a die cavity and sheet can be holder by blank holding
device then with required force the punch can be applied on blank to get desired shape.
➢ In this process to avoid the shearing effects of the blank the die and punch should be provided with
corner radius.
➢ A drawing ratio of 50 % is considered excellent.
➢ In the first case, the action is drawing in which cylindrical stretching of material takes place.
➢ In the second case, there will be bi – axial stretching of the material.
➢ For drawing, the clamping force is just sufficient to prevent buckling of the material at the draw radius
as it enters the die.
➢ The deformation takes place in the flange and over the draw radius.

Special Forming Process Working Principle and Applications

Hydro Forming
8. Explain the process of hydroforming. Explain the types of hydroforming. (Nov/Dec. -2011)
Describe the working principle of hydroforming process with Needs. Also list out its advantages.

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(Apr/May-2023)
Hydroforming is a drawing process. It is forming process in carried out is two ways.
➢ Hydro-mechanical forming
➢ Electro hydraulic forming
Hydro-mechanical forming
➢ In this type of forming process, the punch is connected to the lower die is called male die.
➢ The required shape of inner configuration is made on the punch.
➢ A rubber diaphragm or seal is used for making perfect sealing between male and female die.
➢ This seal is placed across the bottom of the pressure – forming chamber.
➢ The pressure – forming chamber is filled with a hydraulic fluid.
➢ Then, the blank is correctly positioned over the male die or lower die.
➢ Now, the pressure forming chamber done is lowered over the blank in such a way that the reduce is made
to just contact with the blank
➢ After this, hydraulic pressure is applied over the blank.
➢ Simultaneously, the punch is pushed into the blank.
➢ The pressure applied by the hydraulic fluid is increased continuously.
➢ Due to this, the blank metal flows around the punch to from the required shape.

➢ The inverted shape of the punch is made on the blank.

➢ After forming the required shape, the chamber pressure is released.
➢ Then the chamber is raised from the blank.
➢ Finally the blank is stripped out from the punch.
➢ In this case, the required shapes of the blank are obtained only by drawing rather than by bending.
➢ And also, the blank metal is displaced due to plastic flow instead of stretching
Advantages:-
➢ Complicated contours can also be made.
➢ Thinning of metal, spot stresses and spring back are drastically reduced or completely eliminated.
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 ➢ It is used for mass production because the work performed per operation is high.
➢ Tool changing can be done rapidly.
➢ Sharp corners are also possible.
➢ All types of sheet metals can be handled.
➢ Tolerance of 0.005mm/mm are possible practically.
Electro hydraulic forming process.
➢ The working principle of metal forming process is same as that of hydro mechanical forming process.
➢ But, the applied pressure over the blank differs.
➢ Because the pressure inside the pressure forming chamber is produced by electrical means.
➢ The arrangement of this electro hydraulic forming system is shown in fig.
➢ When the supply is given to electrical circuit, a high energy is discharged through a bank of capacitor to
the hydraulic fluid contained to be the chamber.
➢ The discharged energy in the chamber is in the form of shock waves and pressure.
➢ This mechanical energy is used for metal forming operations in the same manner as mentioned in hydro
mechanical forming operations.
Advantages:-
➢ The pressure inside the chamber is high due to combined shock wave & fluid pressure.
➢ Time required per operation is low when compared to hydro mechanical forming operations.

Disadvantages:-
➢ Energy losses occur between electrical components to hydraulic fluid.
➢ Stagnation properties refer to the properties at zero velocity.
➢ Due to shock waves, Drag force is created and finally it results in stagnation pressure in the fluid.

Rubber Pad Forming

9. Explain with a neat sketch the principle and operation of rubber pad forming?(May/June -2013)
Elucidate with a neat sketch rubber pad forming. (Nov/Dec – 2020)
➢ Rubber pad forming process is also called as mar-form process. This process is mainly used for bending
and stretching or drawing operations.
➢ This process is also preferred for quantities of different-shaped machine parts needed at regular
intervals.
➢ For this number of different form blocks called punches are arranged at regular intervals along the
pressing bed called rubber pad.
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 ➢ The pad is made of rubber or polyurethane.
➢ This rubber pad is placed in a ram of a press.
➢ The force applied on the blank by a hydraulic cylinder through the ram and rubber pad.
➢ First the blank is placed over the punch called a male die.
➢ Then the upper pattern called the female part is moved to just touch the top surface of the work. After
this, the force is applied and gradually increased on the blank through the rubber pad.
➢ The blank holder ring is used to distribute uniform pressure throughout the blank.
➢ Thus the required shape is formed on the sheet metal between male and female parts.
➢ The retainers are placed on both sides of the rubber pad.

➢ The function of retainer is to apply essential hydrostatic pressure on the blank and prevents sideward
motion.
➢ Then the rubber pad is released by moving the ram upwards.
➢ Now, the completed shell is stripped out from the punch.
Advantages:
❖ Process is more economical.
❖ Tooling cost is less.
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 ❖ No need of lubricants.
❖ No thinning metal blank takes place.
❖ Tool setting time is less.
❖ Deeper shells can be drawn
Limitations:
❖ Rubber pads will wear out rapidly.
❖ Sharp corners cannot be made accurately.
Applications:
❖ Production of flanged cylindrical and rectangular cups
❖ Production of spherical domes.
❖ Production of parallel & tapered wall shells.
❖ Production of unsymmetrical shape components

Metal Spinning Process

10. Explain the principle of metal spinning process with a neat sketch. (Nov/Dec – 2011, 2019)
The process of forming seamless metal parts from a circular sheet metal or from a tube length on a lathe is
called as spinning process.
Only symmetrical shapes can be produced from metal spinning process.
Methods of the spinning process:-
There are two methods used to produce sheet metal parts.
Manual spinning and Power spinning
Manual spinning:-
➢ First, the circular blank is centered on a lathe which is placed against a form block.
➢ The form block is mounted on the head stock of the spinning lathe.
➢ The blank is tightly held between form block and tail stock spindle.
➢ The required contour surface is made on form block.
➢ The pressure is applied by the roller type forming tool which is placed on the tool post of the spinning
lathe.
➢ The required shape is gradually formed by continuous application of pressure by the roller. During
spinning process, some stretching and thinning of material takes place.
➢ Metal spinning can be done both in add and hot state.
➢ Heat generation due to friction between spinning tool or roller type forming and blank can also be used
to retain the plastic state of sheet metal. Spinning speed varies with size, design, type of metal and
thickness of sheet metal.

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 ➢ Aluminum copper, brass and stainless steel can also be spun in spinning process.
➢ This process is mainly suitable for producing conical shape parts, and suitable for low volume
production.
➢ Components produced in this process do not require any trimming or beading operations.
➢ For producing more complex shapes,segmental chucks made from cast aluminium,magnesium alloys or
hard wood reinforced with cold rolled steel sheets are used.
➢ The lubricants like grease,linseed oil and bees wax are used while using bead and tallow between form
tool and blanks during spinning process.
Advantages:
✓ Parts not be drawn by drawing operations can be easily spin.
✓ Heat generated due to friction is used to retain the sheet metal in the plastic state.
✓ The process is more economical for low volume production.
Disadvantages:
➢ Thinning takes place during spinning process.
➢ For more complex shapes, require segmental chucks. Finally, it leads to increase in cost.
➢ Accuracy and quality of finished products mainly depends on the skill of the operator.
Power spinning process:-
➢ The quality of finished products mainly depends on the skill and experience of the operator. Accuracy
of the finished products is also less in manual spinning process.
➢ Even though segmental chucks are used for making complex shapes, the metal thickness and contour
shapes are restricted in manual spinning.
➢ In order to ensure skill of the operator and reduced machining time, spinning machines are referred as
power spinning.
➢ In power spinning process, the action of form tool is controlled either by any tracer mechanism or by
numerical controls.
➢ Nowadays, computer controlled numerical machines are used to change the shape of contour whenever
we want from the existing program.

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 Advantages:-
➢ Accuracy and quality can be maintained.
➢ It is suitable for high volume production
➢ Time taken to spin the sheet metal is greatly reduced
Application:-production of missile, radar units, jet plane components tanks, air conditioning units and heating
plants.

Introduction Explosive Forming

11. With a neat diagram, explain the principle of explosive forming.(Nov/Dec - 2012, 2013)
Enumerate about standoff method of Explosive forming. (April/May – 2019)
Explain the Explosive forming technique with neat diagram. (Nov/Dec – 2021)
Explain the principle of explosive forming with a need sketch. State. Its applications, advantages and
disadvantages. (Apr/May-2023)
Explosive forming process is used for blanking, cutting, expanding, coining, embossing, flanging, powder
compacting, drawing and sizing operations etc.
Explosives are used in various forms such as rod, sheet granules, liquid, stick etc. According to the placement
of explosive, the operations can be divided into two categories.
1. Standoff operations.
2. Contact operations.
Standoff operations
In this case, the explosive charge is located at some distance away from the blank and it energy is transmitted
through some fluid medium such as water. This technique is used to form blanks into various shape except
welding, hardening, compacting, cutting process.
➢ So, the sheet metal is formed in standoff operation method. In this process, the forming of sheet metal
is done by generating pressure wave in a fluid.
➢ The pressure wave is generated by detonating the enough quantity of explosives.
➢ The blank being formed is placed against the female die. This female die has the required configurations.
➢ This entire setup of female die and blank is placed inside the work tank.
➢ The work tank contains water to receive vibrations in the form of pressure wave.
➢ Then one same conduit is filled with charge or explosives which is also placed inside the work tank.
➢ The work tank should be perfectly insulated to avoid heat transfer from system to surrounding. Now, the
explosive charge is ignited by the detonator.
➢ Due to this a high pressure energy is released in the form of waves and pulse (vibration) on the water
contained in the work tank.
➢ This pressure waves are applied over the blank to obtain the required shape of female die.
➢ The applied pressure by this process may vary from several hundred to thousands of Kg/cm2 with several
hundred m/s displacement velocity.

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At any given distance from the explosive charge center, the high intensity portion of the pressure pulse
generated by the detonating explosive, can be approximately represent as,
𝑃 = 𝑃𝑚 𝑒 −𝑡/𝜃
Where, P is Pressure as a function of time.
Pm is peak pressure at that distance
t is the time after arrival of pressure front at the blank surface.
Θ is time constant characteristic of the charge weight, type of explosive and distance from the charge.
Advantages:
➢ Less capital investment.
➢ Presses are not required
➢ Only one die is enough to form the sheet metal.
➢ Required shapes of components are formed in one stroke.
➢ Large and complex shapes can also be handled.
Disadvantages:
➢ Highly trained operators are needed.
➢ Noisy operation.
Applications:
This process is mainly used for producing aerospace components.
Contact operations
➢ In this case, the explosive charge is directly located over the blank. This operation is mainly used for
welding, hardening, compacting and cutting process.
Principle:
➢ The pressure pulse or shock wave produced is in direct contact with the work piece (usually tubular) and
hence the energy is directly applied on the work without any water medium.
➢ The tube collapses into the die cavity and is formed. It is used for bulging and flaring operations.

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 Advantages:
i) Entire shock wave front is utilized as there is no loss in water.
ii) ii) More efficient as compared to unconfined type.
Disadvantages:
i) More hazard of die failure
ii) Vacuum is required in the die
iii) Air present in the work piece (tube) is compressed leading to heating.
iv) Not suitable for large and thick plates. Applications; Bulging and flaring of tubes.

Magnetic Pulse Forming

12. Write short notes on (April/May - 2010)
(i) Magnetic pulse forming
Explain the magnetic pulse forming process with neat diagram. (Nov/Dec - 2019)
Describe the electromagnetic pulse forming process with neat diagram. (Nov/Dec - 2021)
➢ The required shape of sheet metal is obtained by specially designed magnetic coil.
➢ The basic principle is that discharged of a capacitor through a coil over a period of microseconds,
on the blank to obtain the required shape.
➢ During this, the magnetic flux densities of the order of hundreds of kilojoules can be produced.
➢ The basic circuit consists of an energy storage capacitor, a switch, a coil and a power source. The
current through the coil produces a high intensity magnetic field between the coil and the work
piece.
➢ Due to the eddy current in the blank, the magnetic field is restricted over the surface of blank.
➢ Due to the interaction of eddy current on the blank, the applied magnetic field creates an inward
force on the work piece.
➢ The opposing force between work piece and the coil is high. Since, the coil is placed
rigidity. So, the blank is opposed and forced against a coil.

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 ➢ Properly designed coils can be used for compression, expansion or for forming the blank.
➢ Hence, the force in certain regions of the blank is shaped by utilizing massive conducting structure
as flux concentrator device and not connecting it directly to the basic coil.
➢ This process is more suitable for copper, aluminum, and silver and gold.
➢ For non-conducting material, the force must be generated by using conductive material between
the coil and blank for efficient operation.
➢ The coil should be good and perfectly fit in the blank.
Advantages
1. This process is carried out with uniform rate of forming.
2. It is also better process than conventional process for certain materials.
3. The surface finish of the process is an excellent.
4. Time of operation is less as compared to conventional process.
Disadvantages
1. Non – conducting materials are not processed without aid of conducting materials
2. It is limited for sheet metal forming process not a forming bulk material.
Applications
1. Both compression and expansion of circular bar can be carried out.
2. Producing bulging of tube, shrinkage of tube, attaching tubes at end fitting without leaking are

22
 possible.
3. Forming a torque joints, forging of structural joints between tubes are fitting are easily formed.
4. It is used for instrument gear assembly, embossing and sizing of cups etc.,

Peen Forming Process

13. Explain peen forming process with a neat sketch. (April/May-2008)
Peen forming is a process of well – established surface cleaning. In this process, a stream of metal shots are
blasted against the surface of the blank to be made into required shape.
➢ This technique is also known as free- forming technique.
➢ A stream of small steel ball is suddenly forced with very high velocity against the surface of the blank.

➢ This process is used to form various irregular contour surfaces of aluminumSheet and plates.
➢ The length of the contour of the blank to be formed may be larger.Even the required shape can be
obtained by planning the blank on a table or by suspending from a support to blast.
➢ According to the direct shape of contour, the sheet metal or blank is clamped over form blanks during
peening operation.
➢ The peen- formed parts are checked by using templates.
Advantages:-
➢ Complex contours can be produced easily
➢ This process does not require any die and punch
➢ Peening is also used salvages operation for correcting bent or distorted parts.
Disadvantages:
• It requires longer time for forming the required shape.
• It requires additional devices for forcing out metal shots.
Application:
➢ This process is used in producing specific portion on crankshafts, connecting rods and gears.
➢ It is used for producing honeycomb panels like aircraft wings and large tubular shapes.

Super Plastic Forming

14. Super plastic forming. (April/May2010)
Introduction
➢ Super plastic forming (SPF) is a valuable tool for the fabrication of complex parts used in the aircraft
and automobile industries.
➢ It has been used to produce very complex shapes and integrated structures that are often lighter and
23
 stronger than the assemblies are replaced.
➢ Superplasticity of metals is defined as very high tensile elongation, ranging from two hundred to several
thousand percent.
➢ Super plasticity is an ability of certain materials to undergo extreme elongation at the proper temperature
and stain rate.
➢ Components are formed by applying gas pressure between one or more sheets on a die surface, causing
the sheets to stretch and fill the die cavity.
➢ Specific alloys of titanium, stainless steel, and aluminium are commercially available with the fine-
grained microstructure and strain rate sensitivity of flow stress that are necessary for super plastic
deformation.
Process
➢ SPF can be used to produce parts an impossible to form using conventional techniques. During the SPF
process, the material is heated to the SPF temperature within a sealed die.
➢ Insert gas pressure is then applied, at a controlled rate forcing the material to take shape of the die pattern.
➢ The flow stress of the material during deformation increase rapidly with increasing strain rate. Super
plastic alloys can be stretched at higher temperature by several times of their initial length without
breaking.
Some of the materials developed for super plastic forming are;
1. Bismuth-tin (200% elongation)
2. Zinc-aluminium
3. Titanium (Ti-6Al-V)
4. Aluminium-lithium alloys (2090,2091,8090)
Super-Plastic Forming-Process
This method consists in hot forming up to 10000C super plastic alloys by using an inert gas pressured up to 50
bars. Combined with diffusion bonding, this process allows honeycomb structures made of several sheets in a
single operation.

Loading:
The blank is loaded in the form die. The hot press heats the die and the blank to the material super-plastic
temperature.
Forming:
Once the temperature is reached, it is accurately controlled, while the gas pressure slowly inflates the blank.

24
Forming:
The gas keeps inflating the part to fit the die. The material at the super-plastic temperature can allow
up to 500% elongation.

Release:
At the end of the forming cycle, the part perfectly conforms to the die, even in its smallest details.

Advantages of SPF process

Super plastic forming technology offers the potential to reduce the weight and cost of automotive structural
components for advanced vehicle application.
The main advantages of this process are:
1. It is an one step process
2. The process can be used to form complex components in shapes that are very near the final
dimension
3. Higher material elongation.
4. Elimination of unnecessary joints and rivets.
5. Reduction of subsequent machining.
6. Minimizes the amount of scrap produced.
Application:
The process is increasingly being applied in the aerospace industry as a way of manufacturing very
complex geometries
(i) In automotive body component
(ii) In forming of aircraft frames and skins.

25
 (iii)Diaphragm forming of plastics.
(iv) Complex shape parts-window frames, seat structures.

Micro Forming
15. Explain briefly micro forming in sheet metal processes
✓ Sheet metal components are used extensively in various applications such as vehicles, aircraft,
electronics products, medical implants and packaging for consuming goods, typical parts/ components
including car panels, aircraft skins, cans for food and drinks, frames for TV/ computer
screens/monitors/displays, etc.
✓ Concerning miniature/micro-products, sheet metal parts include electrical connectors and lead frames,
micro-meshes for masks and optical devices, micro springs for micro switches, micro-cups for electron
guns and micro-packaging, micro laminates for micro-motor and fluidic devices, micro gears for micro
mechanical devices, casings/housings for micro-device assembly/packaging, micro knives for surgery
etc.,
✓ Traditionally, sheet metals are defined as metal having a thickness of between 0.4 and 6 mm, while
micro-sheet forming usually deals with sheet metals of which the thickness is usually below 0.3 mm.
✓ Therefore, thin strips or coils shall be the proper words for defining these materials.
✓ As with conventional sheet metal forming major material conversion mechanisms in micro sheet forming
include shearing/cutting, bending, unbending, stretching, compressing, stress relaxation etc.,
✓ Being the same as for conventional sheet metal forming, the mechanical properties of the materials such
as elasticity, plasticity, stress strain relations, strain rate, work hardening, temperature effect, anisotropy,
grain size, residual stress, etc., are very important for understanding material deformation/separation
mechanisms.
✓ The effects of grains sizes, orientations and grain boundary properties are especially significant in micro-
sheet forming, considering their effects in the definition of the overall stress/strain relationships, sheared-
section qualities, bending curvatures, spring back phenomenon, stress relaxation, etc.
✓ For given structures, the effects are more significant, if the relative ratios between the grain sizes and
the strip thickness/feature sizes/ part dimensions.
The following sheet forming processes are used in micro forming.
1. Blanking/Punching
2. Bending
3. Deep drawing
Applications
❖ Cellular Telephones
❖ IC Lead frames
❖ Electronics
❖ Healthcare
❖ Miniature Fasteners
❖ Hard Disc Drives
26
 ❖ National Security,Defense & Automobile.

Incremental Forming
16. Discuss on Incremental sheet forming
❖ (It is also known as Single Point Forming) is a sheet metal forming technique where a sheet is formed
into the final work piece by a series of small incremental deformations.
❖ However, studies have shown that it can be applied to polymer and composite sheets too. Generally, the
sheet is formed by a round tipped tool, typically 5 to 20mm in diameter.
❖ The tool, which can be attached to a CNC machine, a robot arm or similar, indents into the sheet by
about 1 mm and follows a contour for the desired part.
❖ It then indents further and draws the next contour for the part into the sheet and continues to do this until
the full part is formed.
❖ ISF can be divided into variants depending on the number of contact points between tool, sheet and die
(in case there is any).
❖ The term Single Point Incremental Forming (SPIF) is used when the opposite side of the sheet is
supported by a faceplate and Two Point Incremental Forming (TPIF) when a full or partial die supports
the sheet.
Advantages
❖ Incremental forming is a dieless metalworking process. Thus it is best suited to produce bespoke or high-
variety products in small lots, in comparison to the conventional metalworking processes (stamping or
press moulding).
❖ This technique also offers the possibility to fabricate complex and/or 3D shapes that were previously
difficult to produce through processes like metal spinning.
❖ The elimination of dies results in the reduction of lead time and cost for small batch manufacturing.

Blanking and Punching

17. Distinguish between blanking and punching operations. Sketch and explain the elastic phase, plastic
phase and fracture phase that take place in a blanking operation. (Nov/Dec. - 2011)
Discuss blanking and punching with three processing phases. (April/May - 2019)

27
1. Blanking
Blanking is the operation of cutting a flat shape from the sheet metal. The metal that is punched out is
called as “blank” and the metal that is left out is called as scrap.
2. Punching
It is the operation of producing the hole on the workpiece by a punch. In punching, the metal removed
is called as scrap, and the metal that is left out called as workpiece.
The process of cutting a straight line across a strip, sheet or bar is known as shearing process. This action
has three important basic stages.
1. Plastic deformation
2. Shear and
3. Fracture
Fig shows the four stages of the shearing process:

a. Plastic deformation: The blades begin to apply pressure, the workpiece start to undergo elastic
deformation. As pressure increases the workpiece undergoes plastic deformation.

28
 b. Shear: The blades begin to penetrate either side which produces shear of work piece along a vertical
line. Work hardening occurs in the centre.
c. Fracture: Fracture lines originating from the point of each blade meet in the centre of the work piece
causing separation before the blades have fully penetrated.

Compound and Progressive Die

18. Briefly explain what are compound die and progressive dies, with suitable sketches. (Nov/Dec. - 2011)
Progressive dies
❖ These dies are designed to perform two or more operations at different stages every time when the ram
descends.
❖ The stock strip is advanced through a series of stations that perform one or more distinct die operations
on the workpiece.
❖ The strip must cover from the first through each succeeding station to produce a complete workpiece.
❖ After that, a complete workpiece is produced with each stroke of the ram.
❖ The stock strip is fed into the die mechanically or by hand.
❖ The primary stop is pushed-in by hand to hold against the lead end of the sheet metal.
❖ The primary die stop is drawn back after the hole is pierced.
❖ The hole is pierced by the piercing die set in the first cutting stroke of the ram.
❖ After the primary die stop is released, the stoke advances to the next station where it contacts the
automatic button die stop.
❖ The correct spacing is obtained by the help of the secondary stop pin.
❖ In the second cutting stroke of the ram, the pilot of the blanking punch enters the pierced hole and ensures
exact alignment of the stock as the part is blanked.
❖ At the same time, the blanking punch descends and shears the metal to form a washer.
❖ While the blanking operation is performed, the piercing punch produces a hole for the next washer at
the first station.
❖ Thus, after the first stroke, when only a hole will be punched, each stroke of the press produces a finished
washer.

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 ❖ The blanking and piercing punches should not be same height.
❖ A stepping is given in order to reduce the forces.
❖ For piercing operations, the punch will have the shear and the die will be flat.
❖ For blanking operation, the punch will be flat and shear is given to the die.
Advantages
1. The number of operations can be performed with a one handling of the
stock strip.
2. For every stroke of the ram, one work piece is made.
3. It is fairly simple to construct and are economical to repair.
4. It is suitable for mass production.

Disadvantages
1. Thin stock of shaft materials may cause trouble by bending or tearing around piloting holes.
2. Workpiece may become dished as they are pushed through the die since they have a little support.
3. It is complicated design of die set as compared with simple dies.
4. The cost of the die set is high when compared to simple die set.
Compound dies:
❖ In a compound die, two or more cutting operation, such as blanking, piercing operations are combined
and carried out in one stroke of the press at one station only.
❖ In order to do this, both the upper and lower elements which are directly opposed to each other. In other
words, the piercing punch acts in the opposite direction with respect to the blanking punch.
❖ It is used for producing a workpieces (washer) which is pierced and blanked at one station and in one
operation. Here, the blanking punch also serves as the piercing die.
❖ The blanking punch and blanking die opening are mounted in an inverted position.
❖ The sidewalls adjacent to the cutting edges of the blanking die opening are straight because the blank
does not pass through the die.
❖ During the part of the stroke, piercing of hole is done on the stock and upon further travel, the blanking

30
 operation is done.
❖ Angular clearance must be provided in the piercing die to allow slugs to drop through the die.
❖ Compound dies are designed in such a way to carry out both the piercing and blanking operations at the
same in a single stroke of ram.
❖ The workpieace will not be progressed to the next stations.
❖ The main different between progressive and compound dies is, “N” numbers of washers can be produced
in “N” stroke of ram in the case of compound dies but “N+1” stroke are needed to produce “N” washers
for progressive dies.
❖ The progressive and compound dies are mainly used to perform cutting operations.
Advantages:
1. More accurate work piece can be produced.
2. Large parts can be blanked in a smaller press, if compound dies are used.
3. Shorter length of strip materials can be used.
4. The cost of producing is very less.
Disadvantages:
1. It is more expensive to construct and repair.
2. It is slower in operation as compared with progressive dies.
3. It is complicated design of the die set when compared to progressive dies.
4. The tonnage requirement is high.

31