Copyright Goodheart-Willcox Co., Inc. 288 288 Modern Metalworking Modern Metalworking Summary • Stamping is a general term used for many press forming operations. • Cutting is the metalworking process in which metal is cut to size for machining. • Cutting techniques developed for volume production are shearing, laser cutting, plasma cutting, waterjet cutting, blanking, punching, and piercing. • Forming is a process in which flat metal blanks fl are made into three-dimensional shapes using a press and die. • A few of the more widely used forming techniques are draw press, Guerin process, Marform process, hydroforming, bulging, stretch forming, bending, and roll forming. • The introduction of super-tough alloys and the need to shape thin, brittle metals has forced industry to develop new ways of working with these metals, such as high energy rate forming or HERF. • Three common HERF processes are explosive forming, electrohydraulic forming, and magnetic forming. Test Your Knowledge Answer the following questions using the information provided in this chapter. 1. ______ is a metalworking process in which metal is cut to size for machining. 2. ______ is a cutting operation that is used to bring sheet and plate stock to a specifi ed size or shape. fi 3. A(n) ______ cutting system uses fast-fl flowing ionized gases and an electric arc to melt and cut metals. 4. ______ involves cutting flat sheet metal to the fl shape and size of the fi nished part. fi A. Bulging B. Piercing C. Blanking D. Drawing 5. What is a progressive die? 6. In the forming process, a press and die are used to make flat metal blanks into fl ______. 7. Briefl describe each of the following forming fly techniques: A. Draw press. B. Guerin process. C. Marform process. D. Hydroforming. E. Bulging. 8. Describe the stretch forming process. 9. ______ is a forming operation in which the surface area of the work is not appreciably changed. 10. What is roll forming? 11. In which type of forming operation is metal shaped in microseconds by a pressure wave generated by chemical explosives? A. Hydroforming B. Explosive forming C. Electrohydraulic forming D. Electromagnetic forming 12. In which type of forming operation is metal shaped by a magnetic field that causes the fi work to collapse, compress, shrink, or expand depending on the design and placement of the coil? A. Hydroforming B. Explosive forming C. Electrohydraulic forming D. Electromagnetic forming Research and Development 1. Engineering. Design a simple blanking die for use in making tool checks and submit your work to your instructor for evaluation. 2. Language Arts. Secure samples of progressive die products from a local manufacturer. Get sections showing the various stages of the operation. Evaluate the sections for any defects. Present these materials to the class. 3. Language Arts. Secure samples of the drawing process at various stages of the draw. Present the samples to the class and explain each stage of the drawing process that made the samples. 4. Language Arts. Secure samples of products made by four of the various cold forming processes covered in this chapter. Present the samples to the class and explain how the cutting or forming processes were used to make them.