2. Chapter 17
Cold Forming Metal Sheet

3. Learning Objectives
Identify the two main categories of stamping operations.
Describe various metal cutting techniques and systems.
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4. Learning Objectives
Explain how shearing, blanking, and piercing operations differ.
Describe common cold forming techniques.
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5. CAREER CONNECTION Ironworker
Assemble metal frames that provide structure and support
Learn through 3- to 4-year apprenticeships
Mentally and physically able to work at great heights

6. Cold Forming Metal Sheet
Cold working
Operations at room temperature
Stamping includes cutting and forming
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7. Cutting Operations Metal cut to size for machining
Few bring material to exact size
Shearing
Brings sheet and plate stock to specified size or shape

8. Laser Cutting Systems
Cut through materials of different sizes, thicknesses, and shapes
Superior edge quality, precision, and accuracy
Bystronic, Inc.

9. Plasma Cutting Systems
Electric arc and ionized gases melt and cut
Computer-controlled
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10. Waterjet Cutting Systems
High-pressure, high-velocity stream of water
Abrasive added for abrasive waterjet cutting
Hydrodynamic machining (HDM)
OMAX Corporation

11. Blanking, Punching, and Piercing
Punch press with a punch and die
Blanking
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12. Blanking, Punching, and Piercing
Progressive die has all cutting and forming dies in one die
Stripper plate prevents sticking
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13. Forming Operations Forming process uses press and die
Flat metal blanks into three-dimensional shapes
Drawing

14. Draw Press Operation
Metal-shaping process on mechanical or hydraulic draw press
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15. Guerin Process Forms shallow parts in rubber dies
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16. Marform Process Forms deep parts in rubber dies
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17. Hydroforming Rubber diaphragm backed up by hydraulic pressure
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18. Bulging Entrapped rubber forming
Rubber transmits pressure to expand metal blank or tube against die
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19. Stretch Forming Metal blank is pulled from edges
Wraps around form block
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20. Bending
Press brake bending
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21. Bending
Tube bending
Allegheny Ludlum Steel Corp.

22. Roll Forming Series of rollers shape metal strip
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23. Environmentally Friendly Machines
GREEN METALWORKING
Environmentally Friendly Machines
Brush worktables reduce noise levels during operation
High-efficiency components
Computer control optimizes use of materials

24. High Energy Rate Forming
Avoid springback
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25. High Energy Rate Forming
Sudden application of large amount of energy
Explosive forming
High-energy pressure pulse from explosive charge
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26. High Energy Rate Forming
Electrohydraulic forming
Controlled discharge of electrical energy produces shock wave
NASA

27. High Energy Rate Forming
Electromagnetic forming
Insulated induction coil around or within the work
Magnetic field causes work to change shape
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28. High Energy Rate Forming
Electromagnetic forming (continued)
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