Unit IV – Sheet Metal Processes

Sheet Metal
 Products made through the sheet metal processing include automobile bodies, utensils,
almirah, cabinet’s appliances, electronic components, electrical parts, aerospace parts,
refrigeration and air conditioning parts etc.
 Sheet metal is generally considered to be a plate with thickness less than about 5 mm.
 Articles made by sheet metal work are less expensive and lighter in weight.
 Sheet metal forming work started long back 5000 BC.
 As compared to casting and forging, sheet-metal parts offer advantages of lightweight
and versatile shapes.
 Because of the good strength and formability characteristics, low carbon steel is the most
commonly utilized in sheet-metal processing work.
 Sheet metal processing has its own significance as a useful trade in engineering works to
meet our day-to-day requirements.
 Many products, which fulfill the household needs, decoration work and various
engineering articles, are produced from sheet metals.
 A good product properly developed may lead to saving of time and money.
Sheet Metal
 In sheet-metal working, there is no need for further machining as required for casting and
forging works.
 The time taken in sheet-metal working is approximately half of that required in the
machining process.
 For carrying out sheet metal work, the knowledge of geometry, mensuration and
properties of metal is most essential.
 In sheet metal work, various operations such as shearing, blanking, piercing, trimming,
shaving, notching, forming, bending, stamping, coining, embossing etc. are to be
performed on sheet metal using hand tools and press machines to make a product of
desired shape and size.
 Generally metals used in sheet metal work are black iron, galvanized iron, stainless steel,
copper, brass, zinc, aluminium, tin plate and lead.
 Bending
 Bending is one of the most common industrial forming operations.
 We merely have to look at an automobile body, appliance, paper clip, or file cabinet to
appreciate how many parts are shaped by bending.
 Furthermore, bending also imparts stiffness to the part by increasing its moment of inertia.
 Note, for example, how corrugations, flanges, beads, and seams improve the stiffness of
structures without adding any Weight.
 As a specific example, observe the diametral stiffness of a metal can with and without
circumferential beads.
Bending
 The terminology used in the bending of a sheet or plate is shown in figure.
 Note that the outer fibers of the material are in tension, while the inner fibers are in
compression.
 Because of the Poisson effect, the width of the part (bend length, L) has become smaller
in the outer region and larger in the inner region than the original width.
 This phenomenon may be observed easily by bending a rectangular rubber eraser and
observing the changes in its shape.
 The bend allowance, Lb, is the length of the neutral axis in the bend; it is used to
determine the length of the blank for a part to be bent.
 The position of the neutral axis, however, depends on the radius and the bend angle.
 An approximate formula for the bend allowance is Lb, = α(R + /kT),
 where α is the bend angle (in radians), T is the sheet thickness, R is the bend radius, and
k is a constant.
 In practice, k values typically range from 0.33 to 0.5.
 For ideal cases neutral axis is at the centre of the sheet thickness, k=0.5.
Bending
Bending force:
 The bending force is the function of the strength of the material, the length of the bend
sheet, thickness of the sheet and the width of the die opening.
➢ Fb= kLT2(UTS)/W
➢ Fb- Bending force
➢ L-length of the sheet
➢ T- thickness of the material
➢ UTS- Ultimate tensile strength of the material
➢ W-Die opening clearance
 It can be shown that the engineering strain on the outer and inner fibers of a sheet during
bending is given by the expression
Bending
 Minimum Bend Radius: The radius at which a crack first appears at the outer fibers of a
sheet being bent is referred to as the minimum bend radius.
 The bend radius usually is expressed in terms of the thickness, such as 2T, 3T, 4T, and so
on.
 Thus, a 3T minimum bend radius indicates that the smallest radius to which the sheet can
be bent without cracking is three times its thickness.
 The minimum bend radius, R, is, approximately,
 where r is the tensile reduction of area of the sheet metal.
• Springback: Because all materials have a finite modulus
of elasticity, plastic deformation always is followed by
some elastic recovery when the load is removed.
• In bending, this recovery is called springback, which can
be observed easily by bending and then releasing a piece
of sheet metal or wire.
• Springback occurs not only in flat sheets and plates, but
also in solid or hollow bars and tubes of any cross
section.
Compensation for Springback:
 Springback in forming operations usually is compensated for by overbending the part.
 Several trials may be necessary to obtain the desired results.
 Another method is to coin the bend area by subjecting it to highly localized compressive
stresses between the tip of the punch and the die surface, a technique known as
bottoming the punch.
 To compensate for springback two methods are commonly used:
➢ Overbending—the punch angle and radius are smaller than the final ones.
➢ Bottoming—squeezing the part at the end of the stroke.
 Bending in a Four-slide Machine: Bending relatively short pieces can be done on a
machine. In these machines, the lateral movements of the dies are controlled and
synchronized with the vertical die movement to form the part into desired shapes.
 Roll Bending: In this process, plates are bent using a set of rolls. By adjusting the
distance between the three rolls, various curvatures can be obtained. This process is
flexible and is used widely for bending plates for applications such as boilers,
cylindrical pressure vessels, and various curved structural members.
 Beading: In beading, the periphery of the sheet metal is bent into the cavity of a die.
The bead imparts stiffness to the part by increasing the moment of inertia of that
section. Also, beads improve the appearance of the part and eliminate exposed sharp
edges that can be hazardous.
 Flanging: This is a process of bending the edges of sheet metals, usually to 90°. In
shrink flanging, the flange is subjected to compressive hoop stresses that, if
excessive, can cause the flange periphery to wrinkle. The wrinkling tendency
increases with decreasing radius of curvature of the flange. In stretch flanging, the
flange periphery is subjected to tensile stresses that, if excessive, can lead to
cracking along the periphery.
 Roll Forming: This process, which is also called contour-roll forming or cold-roll
forming, is used for forming continuous lengths of sheet metal and for large
production runs. As it passes through a set of rolls, the metal strip is bent in
consecutive stages. The formed strip is then sheared into specific lengths and
stacked continuously.
 Hemming and Seaming: In the hemming process (also called flattening), the edge of
the sheet is folded over itself. Hemming increases the stiffness of the part, improves
its appearance, and eliminates sharp edges. Seaming involves joining two edges of
sheet metal by hemming. Double seams are made by a similar process using
specially shaped rollers for watertight and airtight joints, such as are needed in food
and beverage containers.
Embossing
 With the help of operation, specific shapes of the figures are produced on the sheet
metal
 It is used for decorative purposes or giving details like names, trademarks, etc on
the sheet metal.
Coining (squeezing)
 In coining operation, the metal having good plasticity and proper size is placed within the
punch and die and a tremendous pressure is applied on the blank from both ends.
 Under severe compressive loads, the metal flows in the cold state and fills up the cavity
of the punch and die.
 The operation is used in the manufacturing of coins, ornamental parts etc.
Drawing
 Drawing is the process of making cups, shells,
and similar articles from metal blanks.
 Typical tools used for drawing are shown.
 The set up is similar to that used in blanking
except that the punch and die are provided with
the necessary rounding at the corners to allow
for the smooth flow of metal during drawing.
 Shallow drawing:
➢ Shallow drawing is defined as that where the
cup height is less than half the diameter.
 Deep drawing:
➢ For drawing deeper cups it is necessary to make
specific provisions to confine the metal in order
to prevent excess wrinkling of the edges.
➢ For this purpose, a blank holder is normally
provided on all deep drawing dies.
Stretch forming
 This method was developed during
world war II as a means for producing
large accurately contoured sheets for
aircraft wing and fuselage parts.
 Since then, the method has been
developing rapidly.
 Stretch forming is the process of
forming sheets and profiles by the
combined application of tensile and
bending forces.
 In other words, the stretch forming of
sheet blanks can be defined as the
deepening by a fixed punch of an area
of a sheet clamped rigidly at the edges.
Stretch forming
 The sheet blank can then be formed either between rigid tool parts or be pulled between
two gripping jaws.
 The gripping jaws can be either rigid or can be moved during the application of the
tensile force.
 In general, stretch forming is used to produce basically convex forms and parts with
large radii of curvature. Examples of such forms are external body parts, planking parts for
the aerospace industry and parts of train coaches and wagons.
 Other parts which can be produced by this method are relatively steep U-forms, e.g.
the leading edges of aeroplane wings, with the limitation that the contour is curved in only
one direction.
Formability
 Formability is the ability of sheet metal to undergo shape change without
failure by necking or tearing.

(a) Yield-point elongation in a sheet-metal specimen. (b) Lueder's bands in a low-carbon

steel sheet. Source: Courtesy of Caterpillar Inc. (c) Stretcher strains at the bottom of a
steel can for household products.
Formability Tests for Sheet Metals
Cupping Tests: (Erichsen test)
 The earliest tests developed to predict sheet-
metal formability were cupping tests.
 In the Erichsen test, the sheet specimen is
clamped between two circular, flat dies and a
steel ball or round punch is forced into the sheet
until a crack begins to appear on the stretched
specimen.
 The punch depth, d, at which failure occurs is a
measure of the formability of the sheet.
 Although this similar tests are easy to perform,
they do not simulate the exact conditions of
actual forming operations and hence are not
particularly reliable, especially for complex
parts.
Formability Tests for Sheet Metals
Forming-limit Diagrams:
 An important advance in testing the formability of sheet metals is the development of
forming-limit diagrams (FLD).
 A forming-limit diagram for a particular metal is constructed by first marking the flat sheet
with a grid pattern of circles, using chemical or photoprinting techniques.
 The blank then is stretched over a punch, and the deformation of the circles is observed
and measured in regions where failure has occurred.
 Although the circles typically are 2.5 to 5 mm in diameter, for improved accuracy of
measurement, they should be made as small as in practical.
Forming-limit Diagrams
 In order to develop unequal stretching to simulate actual sheet-forming operations, the flat
specimens are cut to varying widths and then tested.
 After a series of such tests is performed on a particular sheet metal and at different widths,
a forming-limit diagram is constructed showing the boundaries between failure and safe
regions.
 In order to develop a forming-limit diagram, the major and minor engineering strains, as
measured from the deformation of the original circles, are obtained.
 Note in Fig. that the original circle has deformed into an ellipse. The major axis of the
ellipse represents the major direction and magnitude of stretching.
 The major strain is the engineering strain in this direction and is always positive, because
the sheet is being stretched.
 The minor axis of the ellipse represents the magnitude of the stretching or shrinking in the
transverse direction.
 Forming-limit Diagrams
 The data thus obtained from different
locations in each of the samples are then
plotted as shown in Fig.
 The curves represent the boundaries
between failure zones and safe zones for
each type of metal, and as can be noted, the
higher the curve, the better is the
formability of that particular metal.
 As expected, different materials and
conditions (such as cold worked or heat
treated) have different forming-limit
diagrams.
Special forming processes
Hydroforming:
 Hydroforming, sometimes referred to
as fluid forming or rubber diaphragm
forming was developed during the late
1940s and early 1950s in response to a
need for a lower cost method of
producing relatively small quantities of
deep drawn parts.
 Hydroforming, in simple terms,
replaces the punch in traditional
stamping with liquid to provide shaping
force.
 In hydroforming operation, the rubber
diaphragm is pressurized by fluid and
which act as both the flexible tool and
blank holder for forming process.
Hydroforming
 The fluid backed augmented increase the draw depth and reduction of local stress
concentration induced.
 These set up to reduce the defects in formed parts and increase the formability.
 The container is having high pressure of fluid until maximum pressure of 150 MPa used.
These fluid container is fixed on bed press.
 The rubber diaphragm is placed in between pressurized fluid and the blank. The draw
ring is mounted on blank.
 The punch move upward and create high pressure of fluid in the blank and then the punch
travel into container, the cup is formed together and again hydro static pressure is
developed in the fluid.
 The rigid tool is act as punch in the forming. After form of cup, the punch released along
with the draw ring.
 The hydraulic pressure of fluid exerted in the blank, when the stress is controlled
uniformly and accurately.
 And also that allow dimensional control and product is free from tearing and wrinkling.
Hydroforming
Advantages of hydroforming:
 The cost of tool is low
 Flexible and ease operation
 Die wear is low
 Wrinkling and tear on the plate avoided
 The complex shape can be manufactured.
 The laminate sheets are formed also.
Limitations:
 Cycle times are slower than traditional stamping methods.
Applications:
 In automotive industry, the process delivers hollow parts such as radiator frames, engine
cradles, exhaust manifolds, roof and frame rails and instrument panel supports.
 Various rails, manifolds and supports find use in aircraft and appliance applications.
Rubber pad forming
 Rubber forming uses a flexible material, such as rubber or polyurethane, to form a sheet
metal work piece.
 Often the rubber is incased in a steel container and serves as a punch. A work piece is
placed over a rigid die.
 The punch forces the work into the rubber. Rubber is forced all around the work,
creating pressure and forming the metal onto the die.
 This is known as the Guerin process.
Rubber pad forming
 Rubber forming processes are limited in the depth of parts they can produce.
 Limitations in manufacturing exist because the pressure generated by the rubber is
low, only 1500 lbs/in2, (10MPa).
 The same rubber punch or die can be used for many different forming blocks.
 Rubber forming is used in the aircraft industry to produce sheet metal components.
 Low cost tooling makes setup for rubber forming inexpensive.
 This manufacturing process is useful for the production of small quantities of parts.
Rubber pad forming
 Metal spinning
 Metal spinning is a forming process which produces
hollow parts that are typically circular in cross-
section.
 The basic spinning process starts with a flat metal
disc (blank) which rotates on a lathe.
 This rotating blank is pressed against a tool
(mandrel, chuck) which duplicates the interior of
the part.
 This pushing action over the tool results in a formed
part.
 The basic metal spun shapes are the hemisphere,
cone, cylindrical shell, and venturi, etc.
 The thickness of the spun part is nearly the same as
the thickness of the undeformed blank.
 t - upto 6mm for soft non-ferrous metals and upto
5mm for low carbon steel
Metal spinning
 Metal spinning used to be associated with prototypes and low volume production only.
 However, with the introduction of automatic lathes, spinning is now a cost effective
option for both medium and high volume production.
 The relatively inexpensive tooling price for spinning still makes this forming method a
cost effective one for fabricating prototypes.
 The diagram shows a basic setup for a horizontal spinning lathe.
 The tool (mandrel, chuck) is mounted to the headstock of the lathe. A follower block (tail
block) is mounted to the tailstock.
 A circular blank is then clamped to the tool by advancing the follower.
 The tool rest and pin provide a support system for the lever arms, applies pressure to the
blank via a roller or other forming tool.
 The movement of the roller across the blank is called a pass.
 A series of passes, which ultimately forms the completed part, is achieved by
repositioning the lever arms incrementally.
Metal spinning
High Energy Rate Forming processes
 In these forming processes large amount of energy is applied for a very short interval of
time.
 Many metals tend to deform more readily under extra – fast application of load which
make these processes useful to form large size parts out of most metals including those
which are otherwise difficult to form.
 The parts are formed at a rapid rate, and thus these processes are also called high –
velocity forming processes.
 There are several advantages of using these forming processes, like die costs are low,
easy maintenance of tolerances, possibility of forming most metals, and material does
not show spring-back effect.
 The production cost of components by such processes is low. The limitation of these
processes is the need for skilled personnel.
 There are three main high energy rate forming processes: explosive forming, magnetic
forming, and electro hydraulic forming.
Explosive Forming
 Explosive forming, is distinguished from conventional forming in that the punch or
diaphragm is replaced by an explosive charge.
 The explosives used are generally high – explosive chemicals, gaseous mixtures, or
propellants.
 There are two techniques of high – explosive forming: stand – off technique and the
contact technique.
Explosive Forming
 Standoff Technique: The sheet metal work piece blank is clamped over a die and the
assembly is lowered into a tank filled with water.
 The air in the die is pumped out. The explosive charge is placed at some predetermined
distance from the work piece.
 On detonation of the explosive, a pressure pulse of very high intensity is produced. A gas
bubble is also produced which expands spherically and then collapses.
 When the pressure pulse impinges against the work piece, the metal is deformed into the
die with as high velocity as 120 m/s.
 The use of water as the energy transfer medium ensures a uniform transmission of energy
and muffles the sound of the explosive blast.
 The process is versatile – a large variety of shapes can be formed, there is virtually no
limit to the size of the work piece, and it is suitable for low – quantity production as well.
 The process has been successfully used to form steel plates 25 mm thick x 4 m diameter
and to bulge steel tubes as thick as 25 mm.
Explosive Forming
 Contact Technique: The explosive charge in the form of cartridge is held in direct
contact with the work piece while the detonation is initiated.
 The detonation builds up extremely high pressures (upto 30,000MPa) on the surface of
the work piece resulting in metal deformation, and possible fracture.
 The process is used often for bulging tubes.
Applications:
 Explosive forming is mainly used in the aerospace industries but has also found
successful applications in the production of automotive related components.
 The process has the greatest potential in limited – production prototype forming and for
forming large size components for which conventional tooling costs are prohibitively
high.
Magnetic pulse forming
Electro Magnetic Forming
 The process is also called magnetic pulse forming and is mainly used for swaging type
operations, such as fastening fittings on the ends of tubes and crimping terminal ends of
cables. Other applications are blanking, forming, embossing, and drawing.
 The work coils needed for different applications vary although the same power source
may be used.
 To illustrate the principle of electromagnetic forming, consider a tubular work piece.
This work piece is placed in or near a coil.
 A high charging voltage is supplied for a short time to a bank of capacitors connected in
parallel.
 When the charging is complete, which takes very little time, a high voltage switch
triggers the stored electrical energy through the coil. A high – intensity magnetic field is
established which induces eddy currents into the conductive work piece, resulting in the
establishment of another magnetic field. The forces produced by the two magnetic fields
oppose each other with the consequence that there is a repelling force between the coil
and the tubular work piece that causes permanent deformation of the work piece.
Magnetic pulse forming
Magnetic pulse forming
 Either permanent or expandable coils may be used. Since the repelling force acts on the
coil as well the work, the coil itself and the insulation on it must be capable of
withstanding the force, or else they will be destroyed. The expandable coils are less
costly and are also preferred when high energy level is needed.
 Magnetic forming can be accomplished in any of the three ways (swaging, expanding,
embossing or blanking), depending upon the requirements.
Applications:
 Electromagnetic forming process is capable of a wide variety of forming and assembly
operations. It has found extensive applications in the fabrication of hollow, non –
circular, or asymmetrical shapes from tubular stock. The compression applications
involve swaging to produce compression, tensile, and torque joints or sealed pressure
joints, and swaging to apply compression bands or shrink rings for fastening
components together. Flat coils have been used on flat sheets to produce stretch
(internal) and shrink (external) flanges on ring and disc – shaped work pieces.
 Electromagnetic forming has also been used to perform shearing, piercing, and
rivetting.
Peen forming
 It is also called as shot peening. The free forming obtain where the steam of small steel
balls are forced together again the metal surface, when the metal forming process
restricted to fulfillment of fairly specialized function.
 The peen forming is used to form of various irregular shapes on the aluminium sheet
plate. That requires large plate and small control in the process.
Peen forming
 The peen forming process not requires any die and forming press.
 The part to be made by the sheet metal placed on block or it suspended from support
and it has blasting together with shot, small steel balls.
 During the operation blanks are clamped over simple form blocks. The ball forced by
compressed air or rotating blade.
 The ball is having high velocity directly imping the sheet metal to the form of block.
 There is repeated force by sheet metal get the require form block shape.
 The numerous small balls is having diameter of 2.5 mm size cast- steel ball blast again
the metal surface.
 The ball discharged from the rotating wheel or by air blast from nozzle.
 The balls travelling speed of 60 m/s.
 The residual stress are induced to the compressive surface which improve the fatigue
strength of sheet metal.
Peen forming
Advantages:
 Tooling cost will be low
 Require no maintenance cost of tooling
 The compound curvatures are easily produced
 It is a die less forming, So that require minimum lead time
 That process permit rework and design changes for improve the fitness of sheet metal.
Disadvantages:
 Requires longer time for forming.
 Additional devices required for forcing out metal shots.
Applications:
 Provide smoothing and complex curvature of aircraft wings
 Large tubular shapes
 Military air craft
Superplastic forming
Superplastic forming
Superplastic forming
Superplastic forming
Quiz
The volume of metal that enters the rolling stand
 a. should increase after rolling process
 b. should decrease after rolling process
 c. should remain same after rolling process
 d. unpredictable
 ANSWER: should remain same after rolling process
Which characteristic of material is used in forging process?
 a. characteristics of elasticity of material
 b. characteristics of ductility of material
 c. characteristics of plasticity of material
 d. none of the above
 ANSWER: characteristics of plasticity of material
How does the ability of material to withstand unpredictable
loads change after forging?
 a. The ability of material to withstand unpredictable loads
increases after forging
 b. The ability of material to withstand unpredictable loads
decreases after forging
 c. The ability of material to withstand unpredictable loads
does not change after forging
 d. Unpredictable
 ANSWER: The ability of material to withstand
unpredictable loads increases after forging
 Impact extruded parts should be symmetrical in order to
 a) minimize tooling deflection
 b) maintain unequal wall thickness
 c) both a & b
 d) Neither a nor b
 ANSWER: both a & b
Removing the pieces from the edge in shearing operation is
known as?
 a) Perforating
 b) Parting
 c) Notching
 d) Lancing
 Answer: c Notching
Leaving a tab without removing any material is known as?
 a) Perforating
 b) Parting
 c) Notching
 d) Lancing
 Answer: d Lancing
Which of the following operation can be performed on
lathe?
 a) spinning
 b) drawing
 c) coining
 d) swaging
 Answer: spinning
As the clearance increases, the punch force required?
 a) Decreases
 b) Increases
 c) Remains same
 d) First increases then decrease
 Answer: a Decreases
 In a blanking operation, the clearance is provided on
 (A) the die
 (B) both the die and the punch equally
 (C) the punch
 (D) neither the punch nor the die
 ANSWER: the punch
 What is the process, in which the metal is caused to flow
through a restricted orifice to create an extremely
elongated strip of uniform and comparatively smaller
cross-sectional area, called?
 a. Rolling
 b. Extrusion
 c. Drawing
 d. Spinning
 ANSWER: Extrusion
Which of the following is not improved by cold working of
metals?
 a)hardness
 b)toughness
 c)surface finish
 d)corrosion resistance
 ANSWER: d)corrosion resistance
In circular drawing process, when the depth of drawing is
more than the diameter of the die, then the process is called
as
 a. forced drawing
 b. hollow drawing
 c. deep drawing
 d. all of the above
 ANSWER: deep drawing
The ductility of a material with work hardening
 (A) increases
 (B) decreases
 (C) remains unaffected
 (D) unpredictable
 Answer: decreases
Shearing the sheet into two or more pieces is known as?
 a) Perforating
 b) Parting
 c) Notching
 d) Lancing
 Answer: b Parting
Machine forging is used to make parts in
 (A) Open impression dies that involves only upsetting operation
 (B) Closed impression dies that involves only upsetting operation
 (C) Closed impression dies that involves only drawing out
operation
 (D) Open impression dies that involves only drawing out
operation
 Answer: (B) Closed impression dies that involves only upsetting
operation
In which of the following forging operation no special die
is used?
 a) Drop forging
 b) Smith forging
 c) Coining
 d) Press forging
 Answer: b Smith forging
 As the thickness of sheet is increased the clearance
needed will also?
 a) Increase
 b) Decrease
 c) No effect
 d) First decrease then increase
 Answer: Increase
Heading is a kind of which forging operation?
 a) Piercing
 b) Embossing
 c) Upsetting
 d) Coining
 Answer: c Upsetting
 Which of the following is true for hot extrusion?
 a) less force is required in forward extrusion as compared to
backward extrusion
 b) more force is required in forward extrusion as compared to
backward extrusion
 c) same force is applied in both forward and backward extrusion
 d) any of the above
 Answer: b) more force is required in forward extrusion as
compared to backward extrusion
Which operation is used in making raised figures on sheets
with its corresponding relief on the other side?
 a) Roll forging
 b) Embossing
 c) Coining
 d) Heading
 Answer: b Embossing
 Which of the following is not true for cold working of metals?
 a) residual stresses are set up in the metal
 b) stress required to cause deformation is less than hot working of
metals
 c) it reduces the corrosion resistance of the metal
 d) distortion of grains takes place in most of the cold working
processes
 Answer: b) stress required to cause deformation is less than hot
working of metals
Match the correct combination for following metal working
processes.
 Processes Associated state of stress
 P : Blanking 1. Tension
 Q : Stretch Forming 2. Compression
 R : Coining 3. Shear
 S : Deep Drawing 4. Tension and compression
 5. Tension and shear
 (A) P-2, Q-1, R-3, S-4
Blanking Shear
 (B) P-3, Q-4, R-1, S-5 Stretch Forming Tension
 (C) P-5, Q-4, R-3, S-1 Coining Compression
Deep Drawing Tension and compression
 (D) P-3, Q-1, R-2, S-4
 Ans D P-3, Q-1, R-2, S-4
In the deep drawing of cups, blanks show a tendency to wrinkle up
around the periphery (flange). The most likely cause and remedy of
the phenomenon are, respectively,
 (A) Buckling due to circumferential compression; Increase blank
holder pressure
 (B) High blank holder pressure and high friction; Reduce blank
holder pressure and apply lubricant
 (C) High temperature causing increase in circumferential length;
Apply coolant to blank
 (D) Buckling due to circumferential compression; decrease blank
holder pressure
 Ans A Buckling due to circumferential compression; Increase
blank holder pressure