In this article we mainly focus on sheet metal cutting operations and other two we will discuss into upcoming articles. Fundamental concepts of metal forming technology nptel. Apply to sheet metal mechanic, metal fabricator, supply manager and more. Metal forming processes can be classified under two major groups. Metal work piece is heated above recrystalline temp from 1900 to 24000c. They include a very wide range of consumer and industrial products, such as beverage cans, cookware, file. Apr 15, 2017 sheet metal drawing is a more complex operation than cutting or bending operation, and more things can go wrong during sheet metal drawing. Progress in blankholder systems in the pulsating blankholder system the blankholder is subjected to a vibratory pulsating force.
It means cutting a whole piece from sheet metal just enough scrap is left all around the opening to assure that the punch has metal to cut along its entire edge. Sheet metal fabrication is a classification of manufacturing processes that shape a piece of sheet metal into the desired part through material removal andor material deformation. Typically, sheets of metal are sold as flat, rectangular. Using numerical control shearing machine for net size blanking, this is specially. This lecture describes the fundamentals of sheet metal operations including working principle, mechanisms involved and various processes etc. Sheet metal forming is widely used for producing wide range of products starting from household vessels to aerospace parts, to automobile.
Following is a list of common defects during sheet metal operation, with sketches are shown in figure 1. The standard sizes of metal sheets available in the market are quite large. Progressive tool design and analysis for 49 lever 5 stage tools h. A sheet formed part is usually obtained through a number of operation phases final surface intermediate surface each. Sheet metal drawing is a more complex operation than cutting or bending operation, and more things can go wrong during sheet metal drawing. Process design is the ensemble of operations leading from the design geometry to. Sheetmetal characteristics elongation the capability of the sheet metal to stretch without necking and failure. Avoid large sheet metal parts with small bent flanges. They cannot be separated easily by application of forces. Jul 28, 2009 lecture series on manufacturing processes i by prof.
Lecture series on manufacturing processes i by prof. Pulla reddy engineering college, autonomous, kurnool abstract. Joining of materials joining includes welding, brazing, soldering, adhesive bonding of materials. Video lesson sheet metal operations video lecture, online training material, list videos, quiz, materials, useful links, documents and discussions for sheet metal operations video lecture, online training material. One or more of these processes is used to take a flat sheet of ductile metal, and mechanically apply deformation forces that alter the shape of the material. Sheet metal operations cutting and related processes. Metal finishing systems l 18007472637 introduction to buffing buffing is the process used to shine metal, wood, or composites using a cloth wheel impregnated with cutting compounds or rouges. Luders bands can be eliminated by coldrolling the thickness by 0. Bending causes no change in the thickness of the sheet metal. A sheet formed part is usually obtained through a number of operation phases.
Sheet metal tools 1 roper whitney hand punch punches up to 14 hole through 16 ga. Mechanics of sheet metal forming college of engineering. Chandramouli associate deanresearch sastra university, thanjavur6 401. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. To understand the concept of shearing of sheet metal let s look at the figure given below. The first one is sheet metal cutting, second one is sheet metal bending or forming and the last one is known as deep drawing. Sheet metal forming is widely used for producing wide range of products starting from household vessels to aerospace parts, to automobile or aircraft bodies. This stress is maximum along the plane is called shear plane. This practical and comprehensive reference gives the latest developments on the design of sheet forming operations, equipment, tooling, and process modeling. Final shape is obtained by applying tensile, shear or combination of forces and stretching or shrinking the sheet metal blanks. These manufacturing process som study notes will help you to get conceptual deeply knowledge about it. Anything thinner is referred to as a foil and thicker is considered as a plate.
Design for manufacturability sheet metal guidelines bends for the ease of manufacturing, multiple bends on the same plane should occur in the same direction. Metal forming processes indian institute of technology guwahati. Different sheet metal operations with diagrams guide by tips. This is nothing but cutting of sheets by shearing action.
Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 1 of sheet metal operations other sheet metal forming processes r. We are here to provides you the best study notes from best. May 07, 2017 mainly sheet metal process can be divided into three types. Sheet metal forming involves forming and cutting operations performed on metal sheets, strips, and coils. Diy sheet metal bender machine making metal rolling machine in home workshop duration. Yieldpoint elongation lueders bands on lowcarbon steels and almg alloys. Thus, the free or unfixed edge of the sheet metal piece is bent to make the forming process.
Lowcarbon steel is the most commonly used sheet metal because of its low cost and generally good strength and formability characteristics. Greater the gauge number, thinner the sheet of metal. Maintaining precise material flow characteristics is crucial for producing a highquality stamped part. In this lecture we primarily focus on sheet metal operations that may not require forming press. A number of defects can occur in a sheet metal drawn product. We are here to provides you the best study notes from best coaching like made easy, ace academy etc and lecture notes from best institutions like mit open course, iit nptel, crec tirupati, washington, middle east technical university etc. Sheet metal forming massachusetts institute of technology. Mechanical engineering manufacturing processes i nptel. Aug 22, 2014 manufacturing technology sheet metal operations introduction sheet metal forming is a grouping of many complementary processes that are used to form sheet metal parts. The tool will cut or shear off the metal, provided. This means that single or double sheet can be at any point in the sensor gap flutter, vibrate and still lead to reliable results. Sheet metal forming processes mustansiriyah university. Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of.
Sheet metal operations video lecture, online training material. A sheet formed part is usually obtained through a number of operation phases final surface intermediate surface each operation can be decomposed in several phases. Sheet metal processing the raw material for sheet metal manufacturing processes is the output of the rolling process. Sheet metal operations other sheet metal forming processes. The measuring and marking operations carried over on sheet metal are discussed as under. They are mainly used to assemble many parts to make a system. Nptel mechanical engineering forming sheet metal operations. If the material of the workpiece is ductile, the material flows plastically along the shear plane, forming chip, which flows upwards along the face of the tool. Manufacturing process study notes handwritten free pdf.
Design for manufacturability sheet metal guidelines. Mainly sheet metal process can be divided into three types. The piece detached from the strip is known as blank and is led for further operations. Thus the metal gets compressed very severely, causing shear stress. Metal forming processes indian institute of technology.
The quality of the cut surface is greatly influenced by the clearance. Sheet bending sheet bending is defined as the straining of the metal around a straight axis. If the material of the workpiece is ductile, the material flows plastically. Press working operations or sheet metal operations blanking. In sheet metal working, the metal being processed will have a high surface area to volume ratio. Bulk deformation is characteristic in that the work formed has a low surface area to volume ratio. Sheet metal, which acts as the workpiece in these processes, is one of the most common forms of raw material stock. They produce permanent joint between the parts to be assembled. In sheet metal forming practice, we distinguish five basic modes of. Therefore the first step in any sheet metal process is to cut the correct shape and sized blankfrom larger sheet. Then the other end is forced to strike upon the punch which is free or unfixed.
Progressive tool design and analysis for 49 lever 5 stage tools. Bulk deformation processes and sheet metal working processes. Definitions and classification of metal forming processes. Metal forming is the main method of making metal products and semifinished products. Stretch forming, hydro forming, spinning are some of such processes. Bulk deformation is characteristic in that the work formed has a low.
Video lesson sheet metal operations video lecture, online training material, list videos, quiz, materials, useful links, documents and discussions for sheet metal operations video lecture, online. In low carbon steel sheet metal, the minimum radius of a bend should be onehalf the material thickness or 0. Manufacturing technology sheet metal operations introduction sheet metal forming is a grouping of many complementary processes that are used to form sheet metal parts. Plastic properties of metals are used during the process of metal forming. Typically, sheets of metal are sold as flat, rectangular sheets of standard size. Other machining operations shaping and planing a singlepoint tool moves linearly relative to the work part shaping a tool moves planing a workpart moves broaching performed by a.
Manufacturing processes i nptel online videos, courses. But the required sheet size for making a component may be smaller and hence a standard size sheet may have to be therefore cut into several smaller pieces. The cloth buff holds or carries the compound, while the compound does the cutting. Sep 03, 2017 this lecture describes the fundamentals of sheet metal operations including working principle, mechanisms involved and various processes etc. During bending operation, the metal on the inner side of the neutral plane is compressed, and the metal on the outer side of the neutral plane is stretched. If the sheets are thin and very long, they may be in the form of rolls. Layout the stock strip, preferably using at least three part templates. In a combination tool two or more operations such as bending and. More than 90% of smelted metal is processed by different methods of metal forming.
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