What are the types of press metal forming techniques?

Table of Contents

1. Introduction
2. Types of press metal forming Techniques
   1. Bending
   2. Drawing
   3. Forging
   4. Extrusion
   5. Shearing
   6. Stamping
3. SUNMETAL Company Solutions
4. References

Introduction

Metal forming is a crucial process in the manufacturing industry, involving various techniques that allow for the shaping and forming of metal sheets into desired shapes and configurations. Press metal forming techniques are central to this process, providing efficient and precise methods for producing metal components at scale. This article delves into the different types of press metal forming techniques, offering detailed insights into each method's mechanics and applications.

Types of Press Metal Forming Techniques

Bending

Bending involves deforming metal around a straight axis, creating an angle in the material without changing its thickness. Typically performed using a press brake, bending is essential in producing parts such as brackets and panels. Parameters include:

• Die Angle: Typically 90°, 60°, or custom angles for specific applications.
• Bend Radius: Should be at least equal to the thickness of the material to prevent cracking.
• Material Thickness: Ranges from 0.5 mm to 16 mm for most applications.

Drawing

Drawing involves pulling metal into a cavity to create hollow shapes. This technique is extensively used in manufacturing automotive components like fuel tanks and kitchen sink units. Key parameters include:

• Blank Holder Force: Maintains metal flow, typically ranging from 50 kN to 100 kN.
• Drawing Ratio: Generally between 2.0 to 2.5 for most deep drawing operations.

Forging

Forging is a method where compressive forces shape the metal, widely used for high-strength parts like axles and gears. Parameters are:

• Temperature: Can range from 400°C to 1200°C depending on whether hot, warm, or cold forging is employed.
• Press Capacity: Ranges from 5,000 kN to 50,000 kN for industrial-scale production.

Extrusion

Extrusion presses metal through a die to produce long shapes with a consistent cross-section. Common in producing tubes and rails, its parameters include:

• Extrusion Ratio: Generally between 10:1 and 100:1.
• Extrusion Pressure: Ranges from 500 MPa to 7000 MPa depending on material and application.

Shearing

Shearing cuts metal without forming chips or using burning processes, crucial for cutting sheet metal. Essential parameters:

• Blade Clearance: Typically 5% to 10% of the material thickness.
• Shear Force: Depends on material type and thickness, ranging from 400 kN to 3000 kN.

Stamping

Stamping involves pressing flat sheet metal into a die to obtain a specific shape. Used for producing automotive components and appliances. Parameters include:

• Stamping Pressure: Can range from 100 kN to 20,000 kN depending on the component size and complexity.
• Material Thickness: Typically 0.5 mm to 5 mm.

SUNMETAL Company Solutions

SUNMETAL specializes in innovative press metal forming solutions tailored to diverse industry requirements. Their advanced machinery and techniques optimize parameters to deliver superior quality and precision. Notable solutions include:

• Customized Press Brake Systems for optimized bending operations.
• Integrated Drawing Solutions with adjustable blank holder force.
• High-Precision Forging Equipment for automotive industry demands.
• State-of-the-art Extrusion Lines for lightweight metal applications.
• Efficient Shearing Machines featuring automated blade clearance adjustments.
• Precision Stamping Presses for high-volume production with minimal waste.

References

1. Kalpakjian, S., & Schmid, S. R. (2014). Manufacturing Processes for Engineering Materials. Pearson Education.
2. Groover, M. P. (2010). Fundamentals of Modern Manufacturing: Materials, Processes, and Systems. Wiley.
3. SUNMETAL Company Brochure (2023).