Characteristics of sheet metal forming processes

CHARACTERISTICS OF SHEET METAL FORMING PROCESSES

Each and every sheet metal processes are having different characteristics as follows:

1. Roll forming:

Long parts with constant complex cross sections with good surface finish are produced. It provides high production rate and the tooling cost is high.

2. Stretch forming:

Large parts with shallow contours can be formed. It is suitable for low-volume production and labour cost is high. The tooling and equipment costs depend on the part size to be produced.

3. Drawing:

Shallow or deep parts with relatively simple shapes can be produced. The production rate is high and it involves high tooling cost and equipment cost.

4. Stamping:

It includes a variety of operations such as punching, blanking, embossing, bending, flanging and coining. Simple or complex shapes can be formed at high production rate. Tooling and equipment costs are high, but labour cost is low.

5. Rubber forming:

It includes drawing and embossing of simple or complex shapes. The sheet surface is protected by rubber membranes. There is a flexibility of operation and tooling cost is low.

6. Spinning:

Small or large axisymmetric parts with good surface finish can be formed. Tooling costs is low, but labour cost is high unless operations are automated.

7. Superplastic forming:

Complex shapes with fine detail can be produced with close tolerances. Forming time is long. Hence, production rate is low. However, parts are not suitable for high temperature use.

8. Peen forming:

Shallow contours on large sheets can be formed. There is a flexibility of operation. Equipment costs are high. This process is also used for straightening the parts

9. Explosive forming:

Very large sheets with relatively complex shapes can be produced. Although variety of components can be formed it is mostly used for axisymmetric components. Tooling cost is low, but labour cost is high. This process is suitable for low-volume production. The cycle time is long for forming complex parts.

10. Magnetic pulse forming:

Shallow forming, bulging and embossing operations on relatively low-strength sheets are possible. This process is most suitable for tubular shapes. Production rate is high and requires special tooling.