UNIT:5 

SHEET METAL WORK

BENCH-WORK AND
FITTING
PRESENTED BY :
Dheeraj (2019UME5596)
“Ganjeri Charsi”
“Nsut ka choda”
M.E. 2023, Nsut, Dwarka
 SHEET
METAL WORK
 WHAT IS SHEET METAL?
• Sheet with thickness less than 6mm
• Large surface area to volume ratio (SA/vol.) 

PROPERTIES OF SHEET METAL 

      The material used for the sheet metal should have:
1. Low yield stress (for forming process)
2. Low ultimate strength (for shearing process) 
3. High formability i.e. ability of a sheet to undergo plastic
deformation without being damaged. 
 Stainless steel, copper alloys, aluminium alloys satisfies
the above  mentioned properties.
 EXAMPLES OF SHEET METAL
• ALUMINIUM SHEET: Usually soft and ductile. To enhance
strength iron, silicon, copper are added

• STAINLESS STEEL: It Is an alloy of steel with nickel, chromium

and traces of other metals.It has good corrosive and heat
resistance

• GALVANISED IRON :It is soft steel coated often with molten zinc.
This coating resist rust, improves appearances, solderability,
increases water resistance. It is popularly known as G.I. sheets.

• COPPER SHEET: It is a reddish coloured metal and is extremely

malleable and ductile. Copper sheets have good corrosion
resistance.  
 Sheet classification parameter:
Size / Dimensions

Overall Thickness  This is the overall thickness of stock forms, tube walls, or other fabricated
components. 
Search Logic: User may specify either, both, or neither of the "At Least" and "No More
Than" values. Products returned as matches will meet all specified criteria.

Gauge Thickness  The numerical gauge thickness of the sheet, foil, or wire product.  Different
gauge systems are used for different stock forms and alloy types. 
Search Logic: User may specify either, both, or neither of the "At Least" and "No More
Than" values. Products returned as matches will meet all specified criteria.

Overall Width / OD  This is the overall width or outer diameter (OD) of stock forms such as bars,
plates, and tubes. Overall width is the average particulate diameter for raw
materials such as powders, granules, and pellets. 

Search Logic: User may specify either, both, or neither of the "At Least" and "No More
Than" values. Products returned as matches will meet all specified criteria.

Overall Length  This is the length of stock materials such as bars, rods, plates, and tubes. 
Search Logic: User may specify either, both, or neither of the "At Least" and "No More
Than" values. Products returned as matches will meet all specified criteria.
 Sheet classification parameter:
Mechanical Properties
Tensile Strength Ultimate tensile strength (UTS) at break is the maximum amount of stress required
(UTS, Break)  to fail or break the material under tension-loading test conditions.   
Search Logic: User may specify either, both, or neither of the "At Least" and "No More Than"
values. Products returned as matches will meet all specified criteria.
Yield Strength Yield strength (YS) is the maximum amount of stress required to deform or impart
(YS)  permanent plastic deformation (typically of 0.2%) in the material under tension-
loading test conditions. 

Search Logic: User may specify either, both, or neither of the "At Least" and "No More Than"
values. Products returned as matches will meet all specified criteria.
Elongation  Elongation is the percent amount of deformation that occurs during a tensile test
or other mechanical test. 
Search Logic: User may specify either, both, or neither of the "At Least" and "No More Than"
values. Products returned as matches will meet all specified criteria.
Tensile Modulus Tensile modulus, Young's modulus, or the modulus of elasticity (E) is a material
(E)  constant that indicates the variation in strain produced under an applied tensile
load. Materials with a higher modulus of elasticity have higher stiffness or rigidity. 
Search Logic: User may specify either, both, or neither of the "At Least" and "No More Than"
values. Products returned as matches will meet all specified criteria.
 Examples of std. sheet classification
• Relevant DIN standards for metal sheets
– DIN 1016
Hot-rolled strip / hot-rolled sheet
– DIN 1541
Flat steel products; cold rolled wide mill strip and sheet of unalloyed steels; dimensions,
tolerances on dimensions and form
– DIN 59 232
Hot-dip galvanised wide strip and sheet/plate made of mild unalloyed steels and general
structural steels
– DIN 59 381
Flat steel products; cold rolled strip of stainless and of heat resisting steels
– DIN 59 382
Flat steel products; cold rolled narrow mill strip of stainless steels

• Relevant EN standards for metal sheets

– EN 10 051
Continuously hot-rolled strip and plate/sheet cut from wide strip of non-alloy and alloy
steels
– EN 10 131
Cold rolled uncoated and zinc or zinc-nickel electrolytically coated low carbon and high
yield strength steel flat products for cold forming
– EN 10 143
Continuously hot-dip coated steel sheet and strip
Sheet Metalworking Operation
Cutting and forming operations performed on
relatively thin sheets of metal
Thickness of sheet metal = 0.4 mm (1/64 in) to
6 mm (1/4 in)
Operations usually performed as cold working
Generally combinations of punch and dies are
used to carry out such operations.
Used in manufacturing of bodies of
automobiles, beverage cans, utensils etc.
CLASSIFICATION OF SHEET METAL
OPERATIONS
STRESS INDUCED ​ OPERATIONS ​

Shearing​ Shearing, blanking, piercing,

trimming, notching, nibbling, shaving​

Tension​ Strech forming​

Compression​ Coining, sizing, ironing

Tension and Compression​ Drawing, spinning, bending,

forming, embossing​
SOME COMMON TERMINOLOGIES

• CLEARANCE (c): 
   The distance between
die and punch 
• PENETRATION (p):
   Punching has to be done
till the point where two
propagated cracks meet .
   The depth by which
punch moves into the
sheet metal is called         
penetration depth
More About Clearance

• It depends essentially on material and thickness of

the sheet metal.
   Soft metal: Small clearance
   Hard metal: Large clearance
   Thin metal : Small clearance
   Thick metal: large clearance
 SHEARING ACTION
• The metal is brought to the
plastic stage by pressing the
sheet between punch and die
so that the fracture is initiated
at the cutting points.
• The fracture on the either
side of the sheet propagates as
the punch continues its
downward motion.
• When the two
cracks meet the slug
separates from the parent strip.
 BLANKING AND PIERCING
• When the part that we
have removed is the
desired product, then such
process is called blanking.
•  If the Sheet(with hole) left
after blanking is the
desired product then such
process is called
piercing/ punching. 
 SOME MINOR SHEARING
OPERATIONS
• NIBBLING: It is removing of material in small increments.
The punches used can be round or square depending on the
applications.

• NOTCHING: It is a method to cut a specified small portion of

metal towards the edge of the stock.

• LANCING: It is an operation in which a single line cut or slit is

made part way across the strip stock so that the part can be
bent of formed into required shape without removing any
metal 
PICTORIAL REPRESENTATION
OF MINOR SHEARING
OPERATIONS

NIBBLING: Creating NOTCHING: Cut is LANCING: single

profile by multiple made at edge of line or slit to
overlapping punches. sheet to facilitate facilitate easy
easy bending. bending
 TRIMMING: Punching away
SLITTING: similar to lancing excess material from the
but instead cut is made in perimeter, which is termed
middle  of sheet. as flash.
Eg. Trimming of flange from
the cup
 FORMING OPERATIONS

   DRAWING:
• Used for manufacturing
AXISYMMETRIC shapes
• Rapid and fast process
• Can easily be automated 
• Used for making cups, shells
and similar articles from
metal blanks. 
 SHEARING OPERATIONS v/s
FORMING OPERATIONS
In shearing operations Forming
externally applied load is operations generally deals
more than the ultimate with changing the shape of
stress of the material so the materials
that the material gets therefore stresses
fractured. generated should be more
than the  yielding stress
and less than the ultimate
stress.
   IRONING:
• It is the operation of thinning
the side walls. 
• The die and punch set used is
similar to drawing operations
except the clearance b/w
the die and punch is smaller
than that used in drawing
operations.
• The material gets compressed
b/w the punch and die which
reduces the thickness, and
thus serves our purpose.
 SPINNING
• It is used for making cup shaped
articles which are axisymmetric.
•  The process of spinning consists
of rotating the blank, fixed
against the form block and
then applying a
gradually moving force on the
blank so that blank takes the
shape of the form block.
 SPINNING v/s DRAWING

• Comparable to drawing for making cylindrical

shaped parts
• Because of simpler tools used spinning is
economical for smaller lots
• Complicated shapes are not feasible by drawing
but can be made by spinning using multiple
shapes of form block
• Large parts are much more easily made in
spinning than by drawing
 BENDING
• It refers to operation of
deforming a flat sheet
around a straight axis
where the neutral plane
lies.
• Stresses generated are hig
her than yield stress but
lower than ultimate stress.
• variety of punch and dies
are used to get different
shapes.
 V-DIE U-DIE

NOTE:
In this process the elastic deformation will be recovered while the plastic will remain
the same therefore spring back effect has to be taken into account .
Angle between flanges increases slightly due to spring back 
 STRECH FORMING
• In stretch forming
the complete deformation
is carried out in plastic state
only. Therefore spring back
effect has been nullified. 
• The sheet is held in
the jaws and is stretched
beyond elastic limit .
• The sheet is then brought in
contact with the die as
shown. 
 EMBOSSING
• It is used for making
projections on sheet
metal with corresponding
relief on other side
• Used for producing
figures/letters on  a
sheet metal 
• Involves process of drawing
and bending wherein
suitable impressions are
imposed on die and punch.
 COINING
• Coining is basically a cold forging
operation except for the fact
that the flow of the metal occurs
only at the top layer and not in
the entire volume. 
• The
coining die consists of punch
and die which
are engraved with necessary det
ails required on both the sides
of final object.
• Used for making coins, medals,
decorative items etc.
 COINING v/s EMBOSSING

• In coining we have projections on both

side whereas in embossing we have
projection on one side and corresponding
recession/ relief on the other.
• In coining we can have different types of
impressions on the either side unlike
embossing.
• Merits
-High strength
-Good dimensional accuracy and surface finish
-Relatively low cost
• Demerits
-Wrinkling and tearing are typical limits to drawing operations
-Different techniques can be used to overcome these
limitations
-Draw beads
-Vertical projections and matching grooves in the die and
blank
-Trimming may be used to reach final dimensions
Thank you