sheet metal forming and operations
TRANSCRIPT
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Singh Abhishek Ravinder141080119052Semister-4rd
Mechanical Dept.
MANUFACTURING PROCESS IIGROUP NO:. 9
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SHEET METAL FORMINGAND OPERATIONS
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1.0 Introduction
Sheet metal is simply metal formed into thin and flat pieces. Sheet metal is essentially metal pressed into sheets. These sheets are used at
various places. These sheets can be bent, cut and molded into any shape for use anywhere.
Sheet metal is generally produced in sheets by reducing the thickness of work piece by compressive forces applied through a set of rolls.
Sheets
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Sheet Metal Forming How to differentiate a sheet
and a plate ?
O If thickness is less than 6 mm (1/ 4 inches) then it is regarded as sheet.
O If thickness is greater than 6 mm (1/ 4 inches) then it is regarded as plate.
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Applications of sheet metalsO Aircraft Bodies
O Automobiles bodies
O Utensils used for domestic purposes
O Beverage cans
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Cutting OperationsShearing by two sharp cutting edges.Plastic deformation penetration
fracture
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Shearing, Blanking and Punching
Shearing - Cutting on sheet-metal with straight edges.
Blanking - Cutting sheet-metal with a closed contour.
Punching - Making holes on sheet-metal.
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Sheet-metal Cuttingc = atc = clearancea = allowancet = thickness
Blanking:Blanking punch dia. = Db-
2cBlanking die dia. = Db
PunchHole punch dia. = Db
Hole die dia. = Db+ 2c
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Sheet-metal Cutting
Small clearance
Large clearance
Cutting force = StLS = Shear strength of sheet-metalt = Sheet-metal thicknessL = Length of cutting edgeor, Cutting force = 0.7TtLT = Ultimate tensile strength of sheet-metal
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Sheet-metal Cutting Operations
Cut-off
Parting
Slotting Perforating Notching / Seminotching
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Sheet-metal Cutting Operations
Fine blanking -close tolerances and smooth edges in one step.Trimming - Cutting operation to remove excess metal
Shaving - Shearing with very small clearance to obtain accurate dimensions., secondary or finishing operation.
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Bending
V- bending Edge - bending
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Bending AnalysisBA = 2 A( R + Kbat ) / 360where BA = bending allowance, A = bend angle, R = bend
radius, t = stock thickness, Kba = stretch factor.For R< 2t, Kba= 0.33 ; for R 2t, Kba= 0.5.
Spring back,
where A’ = include angle of sheet-metal part A’b = include angle of bending tool w = width of sheet-metal
Bending force D = die opening dimension Kbf = 1.33 V-bending
Kbf = 0.33 edge bending
b
b
AAASB
DTwtK
F bf2
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Bending AnalysisSpring back
Die-openingdimension
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Bending Operations
Straight flanging Stretch flanging Shrink flanging
Hemming Seaming Curling
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Bending Operations
Channel bending U-bending air-bending
Offset-bending Corrugating Tube forming
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Drawingc = ClearanceDb = blank
diameterDp = Punch
diameterRd = die corner
radiusRp = Punch
corner radius
F = drawing forceFh = holding
force
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Deep Drawing
Initial step bending of edge straightening of side wall
Thinning and drawing final cup shape
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Drawing Defects
a) Wrinkling in flange - small holding forceb) Wrinkling in the wall - insufficient holding
force, wrinkling initially occurring on the flange.c) Tearing - high stress, sharp die radiusd) Earing - anisotropy of the materiale) Surface scratches - Die or punch not having a
smooth surface, insufficient lubrication
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Other Sheet-metal Operations
Ironing - squeezing and drawing in conjunction
Corning & Embossing - to produce surface details
Lancing - combination of cutting and forming
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Other Sheet-metal Operations
Rubber forming processes:
Guerin process - low cost, small volume, pressure up 10 MPa.
Hydroforming - Higher pressure, up to 100 MPa.
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Dies
Components of a punch and die for blanking operation
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DIE CUTTINGO It is combination of following operationsOPerforating.OParting or shearing a sheet into two.ONotching or removing pieces in edges.OLancing or leaving a tab with removing any material
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SLITTINGOShearing operation –using circular bladesOThese blades follow straight line or circular
path or curved path – depending upon requirement.
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NIBBLINGONibbler (tool) move straight up and moves
down rapidly.OSheet metal is fed in gap between two cutting tools and produces overlapping holesOSuitable small runs, several intrcate shapes can be produced.
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PIERCINGO It is a shearing operation.O Creates open hole in sheet metal by
separating the interior section.O Removed metal is discarded as scrap
PART
slug
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BLANKING:
O It is also a shearing operation.O It enlarges earlier pierced hole.O Removed metal is desired one.
PARTPART
SLUG
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OVery smooth and square edges can be obtained by fine blanking.
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DiesProgressive
dies and final part
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Press
Press are driven mechanically or hydraulically.
Knuckle jointcrankshaft
eccentric
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Stretch Forming
Stretching and forming with a die at the same time.
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Roll FormingSimilar to the the rolling process but working on sheet-metal or tubes.
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Spinning
Conventionalspinning
Shear spinning - thinning and bending occur at the same time.
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Spinning
Tube spinning - similar to shear spinning but working on a tube.
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High Energy Forming
Explosive formingElectrohydraulic formingElectromagnetic forming
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Tube Bending
Stretch bending
Drawing bending
Compression bending
R/D 3.0 with mandrelR/D 1.5 without
mandrel
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THANK YOU…