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INTRODUCTION TO SHEET METAL FABRICATION, STAMPING, DEEP DRAWING AND METAL SPINNING

Metal fabrication is the building of metal structures by cutting, bending, and assembling processes. It is a value added process that involves the construction of machines and structures from various raw materials. A fab shop will bid on a job, usually based on the engineering drawings, and if awarded the contract will build the product. Large fab shops will employ a multitude of value added processes in one plant or facility including welding, cutting, forming and machining. These large fab shops offer additional value to their customers by limiting the need for purchasing personnel to locate multiple vendors for different services. Metal fabrication jobs usually start with shop drawings including precise measurements then move to the fabrication stage and finally to the installation of the final project. Fabrication shops are employed by contractors, OEMs and VARs. Typical projects include loose parts, structural frames for buildings and heavy equipment, and stairs and hand railings for buildings.

Forming

Forming is a process of material deformation. Forming is typically applied to metals. To define the process, a raw material piece is formed by applying force to an object. The force must be great enough to change the shape of the object from its initial shape. The process of forming can be controlled with the use of tools such as punches or dies. Machinery can also be used to regulate force magnitude and direction. An example of machine based forming can also combine forming and welding to produce lengths of fabricated sheeting, most commonly seen in the form of linear grating (used principally for water drainage)

Proper design and use of tools with machinery creates a repeatable form which can be used to create products for many industries, including jewelry, aerospace, automotive, construction, civil and architectural, etc.

Stamping

Stamping (also known as pressing) is the process of placing flat sheet metal in either blank or coil form into a stamping press where a tool and die surface forms the metal into a net shape. Stamping includes a variety of sheet-metal forming manufacturing processes, such as punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produces the desired form on the sheet metal part, or could occur through a series of stages. The process is usually carried out on sheet metal, but can also be used on other materials, such as polystyrene.

Stamping is usually done on cold metal sheet. See Forging for hot metal forming operations.

History

Stamped parts were used for mass-produced bicycles in the 1890s. Stamping replaced die forging and machining, resulting in greatly reduced cost. Although not as strong as die forged parts, they were of good enough quality.

Stamped bicycle parts were being imported into the United States from Germany in 1890. U.S. companies then started to have stamping machines custom built by U.S. machine tool makers. Through research and development Western Wheel was able to stamp most bicycle parts.

Several automobile manufacturers adopted stamped parts before Ford Motor Company. Henry Ford resisted the recommendations of his engineers to use stamped parts, but when the company could not satisfy the demand with die forged parts, Ford was forced to use stampings.

Metal stamping can be applied to a variety of materials based on their unique metalworking qualities for a number of applications across a wide range of industries. Metal Stamping may require the forming and processing of base common metals to rare alloys for their application specific advantages. Some industries require the electrical or thermal conductivity of beryllium copper in areas such as aerospace, electrical, and the defense industry or the high strength application of steel and its many alloys for the automotive industry.

Deep drawing

Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. It is thus a shape transformation process with material retention. The process is considered "deep" drawing when the depth of the drawn part exceeds its diameter. This is achieved by redrawing the part through a series of dies. The flange region (sheet metal in the die shoulder area) experiences a radial drawing stress and a tangential compressive stress due to the material retention property. These compressive stresses (hoop stresses) result in flange wrinkles (wrinkles of the first order). Wrinkles can be prevented by using a blank holder, the function of which is to facilitate controlled material flow into the die radius.

Deep drawing has been classified into conventional and unconventional deep drawing. The main aim of any unconventional deep drawing process is to extend the formability limits of the process. Some of the unconventional processes include hydromechanical deep drawing, Hydroform process, Aquadraw process, Guerin process, Marform process and the hydraulic deep drawing process to name a few.

The Marform process, for example, operates using the principle of rubber pad forming techniques. Deep-recessed parts with either vertical or sloped walls can be formed. In this type of forming, the die rig employs a rubber pad as one tool half and a solid tool half, similar to the die in a conventional die set, to form a component into its final shape. Dies are made of cast light alloys and the rubber pad is 1.5-2 times thicker than the component to be formed. For Marforming, single-action presses are equipped with die cushions and blank holders. The blank is held against the rubber pad by a blank holder, through which a punch is acting as in conventional deep drawing. It is a double-acting apparatus: at first the ram slides down, then the blank holder moves: this feature allows it to perform deep drawings (30-40% transverse dimension) with no wrinkles.

Industrial uses of deep drawing processes include automotive body and structural parts, aircraft components, utensils and white goods. Complex parts are normally formed using progressive dies in a single forming press or by using a press line.

Workpiece materials and power requirements

Metal spinning

Metal spinning, also known as spin forming or spinning or metal turning most commonly, is a metalworking process by which a disc or tube of metal is rotated at high speed and formed into an axially symmetric part.[1] Spinning can be performed by hand or by a CNC lathe.

Metal spinning does not involve removal of material, as in conventional wood or metal turning, but forming (moulding) of sheet material over an existing shape.

Metal spinning ranges from an artisan's specialty to the most advantageous way to form round metal parts for commercial applications. Artisans use the process to produce architectural detail, specialty lighting, decorative household goods and urns. Commercial applications include rocket nose cones, cookware, gas cylinders, brass instrument bells, and public waste receptacles. Virtually any ductile metal may be formed, from aluminum or stainless steel, to high-strength, high-temperature alloys. The diameter and depth of formed parts are limited only by the size of the equipment available.