Forming Rolling: plates ( 5 to 12 in thk), sheets (upto 6 mm thk) threads, seamless tubes and pipes. Forging: Aircraft landing gear, jet engine shafts, structural components. Changing the shape of an existing solid body
Forming Extrusion and Drawing: door and window frames, tubing, railings rods, shafts, wires. Sheet metal forming: 1. Shearing 2. Bending metal desks, cabinets, car bodies, fuselage beverage cans.
http://www.youtube.com/watch?v=qTUMbVNf1Xc&feature=related http://www.youtube.com/watch?v=nA8y__BMl-o&feature=related http://www.youtube.com/watch?v=q5Wlr6Co5SI Sheet Metal
Avoid flat bottom holes, give room for tool clearance and chips
DFM considerations Avoid flat bottom holes, give room for tool clearance and chips Limit machining operations
DFM considerations Avoid flat bottom holes, give room for tool clearance and chips Limit machining operations Sharp corners decrease the strength
Sheet Metal Flat pattern Bend Final product Compresses on the Inside, Stretches on the outside Calculating length of Flattened pattern: Bend Allowance. Empirical formula: BA = (0.017453 R + 0.0078 T) N Where R = radius of bend T = metal thickness N = number of degrees of bend
Sheet Metal Calculate Bend Allowance for R = 0.075 inch Thickness T = 0.125 inch Angle N = 90 BA = (0.017453 x 0.075 + 0.0078 x 0.125 ) 90 = 0.20555775 0.2056 in.