Bulk Forming And Sheet Metal Forming

Metal forming processes can be classified under two major groups.

Bulk forming and sheet metal forming.

2012 as semifinished product sheets with an initial thickness of 1 5 mm are used and subjected to one or several conventional bulk forming operations. Sheet metal forming involves forming and cutting operations performed on metal sheets strips and coils. Elastic strain field sheet bulk metal forming means technological processes in which plastic deformation zone size is comparable to the sheet thickness. The pri mary use of the tenn bulk deformation is to distinguish it from sheet fonning processes.

Tion to sheet metal forming at the same time eliminating its disadvantages as far as possible. This includes special meshing technologies for sheet metal structures optimized element formulations and specific functionalities. Thicknesses can vary significantly. Sheet bulk metal forming sheet bulk metal forming comprises the production of sheet metal parts with local functional features such as teeth ribs and solid bosses positioned outside the plane of the sheets from which they are shaped by plastic deformation of sheets and plates with intended three dimensional plastic flow.

For example processes such as forming operation small radius bending and ironing of small sized parts. Extremely thin sheets are considered foil or leaf and pieces thicker than 6 mm 0 25 in are considered. Tools include punch die that are used to deform the sheets. The application of bulk forming processes to sheet or plate semi finished products sometimes in combination with conventional sheet forming processes creates new products with the requested properties.

Upsetting is a typical cold bulk forming operation with linear tool motion and a controlled reduction of at least one workpiece dimension between two tools. Sheet metal is metal formed by an industrial process into thin flat pieces. In sheet forming opera tions the defonnation stresses are usually in the plane of the sheet metal whereas in bulk defonnation the. Bulk deformation is characteristic in that the work formed has a low surface area to volume ratio.

In sheet metal working the metal being processed will have a high surface area to volume ratio. Sheet bulk metal forming sbmf processes are defined as forming of sheets with an intended three dimensional material flow as in bulk forming processes merklein et al. The paper defines this new class of sheet bulk metal forming processes gives an overview of the existing processes belonging to this class. Simulation of titanium cup drawing in qform.

5 are discussed including detailed process analysis and potential industrial applications. Classification of basic sheet forming processes bending deep drawing shearing. Bulk defonnation is a metal fonning process where the defonnation is three dimensional in nature. Bulk deformation processes and sheet metal working processes.

The surface area to volume ratio of the starting metal is relatively high. In the next sections the different sheet bulk metal forming processes illustrated in fig.