FORMABILITY OF SHEET METAL - TEST METHODS AN

INTRODUCTION TO SPECIAL FORMING PROCESSES

FORMABILITY OF SHEET METAL WORK

Formability is the ability of a given metal workpiece to undergo plastic

deformation without being damaged.
The plastic deformation capacity of metallic materials, however, is limited to a certain
extent, at which point, the material could experience tearing or fracture (breakage).
Sheet metal may undergo two basic modes of deformation (a) Stretching (b) Drawing
There are important distinction between these two modes and different parameters
involved in determining formability under these different conditions.

CUPPING TEST:

Anisotropy is an important factor in sheet metal forming. Anisotropy is the directional

variation of mechanical properties.
In other words, the material will react differently to stress applied in one direction
than it would to the same stress applied in a different direction.
If a sheet is isotropic, then its properties are the same in any direction.
Cupping tests can be used to determine anisotropy.
If the fracture occurring due to the applied force through the round ball is circular,
then the sheet is isotropic.
If a straight fracture occurs, this means that the sheet is anisotropic.
 AN INTRODUCTION TO SPECIAL FORMING PROCESSES
RUBBER FORMING
o In rubber forming , one of the dies in a set is made of flexible material, such
as a rubber or polyurethane membrane.
o Polyurethanes are used widely because of their resistance to abrasion, long
fatigue life and resistance to damage by burrs or sharp edges of the sheet
blank. In bending and embossing sheet metal by the rubber forming method,
as shown in the following Figure, the female die is replaced with a rubber pad.
o Parts can also be formed with laminated sheets of various nonmetallic material
or coatings.
o Examples of the bending and the embossing of sheet metal with a metal punch
and with a flexible pad serving as the female die.
TUBE-HYDROFORMING PROCESS
o In tube hydroforming, steel or other metal tubing is formed in a die and
pressurized by a fluid.
o This procedure can form simple tubes or it can form intricate hollow tubes.
o Applications of tube-hydroformed parts include automotive exhaust and
structural components. (a) Schematic illustration of the tube-hydroforming
process. (b) Example of tube-hydroformed parts. Automotive exhaust and
structural components, bicycle frames, and hydraulic and pneumatic fittings
are produced through tube hydroforming.
EXPLOSIVE FORMING PROCESS
o Explosive energy used as metal forming Sheet-metal blank is clamped over a
die Assembly is immersed in a tank with water Rapid conversion of explosive
charge into gas generates a shock wave.
o The pressure of this wave is sufficient to form sheet metals (a) explosive
forming process. (b) confined method of explosive bulging of tubes.