Presentation on theme: "Sheet metal processing"— Presentation transcript:
1 Sheet metal processing Traditional Manufacturing ProcessesCastingFormingSheet metal processingPowder- and Ceramics ProcessingPlastics processingCuttingJoiningSurface treatment
2 Sheet Metal ProcessesRaw material: sheets of metal, rectangular, largeRaw material Processing: Rolling (anisotropic properties)Processes:ShearingPunchingBendingDeep drawingHydroforming
3 ShearingA large scissors action, cutting the sheet along a straight lineMain use: to cut large sheet into smaller sizes for making parts.
4 ShearingShearing is a process for cutting sheet metal to size out of a larger stock such as roll stock. Shears are used as the preliminary step in preparing stock for stamping processes.Material thickness ranges from mm to 6.35 mm (0.005 to in). The dimensional tolerance ranges from ±0.125 mm to ±1.5 mm (±0.005 to ±0.060 in).The shearing process produces a shear edge burr, which can be minimized to less than 10% of the material thickness. The burr is a function of clearance between the punch and the die (which is nominally designed to be the material thickness), and the sharpness of the punch and the die.
5 Blanking / PunchingBlanking and punching are similar sheet metal cutting operations that involve cutting the sheet metal along a closed outline.If the part that is cut out is the desired product, the operation is called blankingand the product is called blank. If the remaining stock is the desired part, the operation is called punching.
7 Cutting tool is a round/rectangular punch, that goes through a hole, or die of same shape
8 Main uses: cutting holes in sheets; cutting sheet to required shape PunchingMain uses: cutting holes in sheets; cutting sheet to required shapenesting of partstypical punched partExercise: how to determine optimal nesting?
9 Body of Olympus E-300 camera BendingBody of Olympus E-300 cameracomponent with multiple bending operationscomponent with punching,bending, drawing operations[image source: dpreview.com]
21 (a) Compensation: the metal is bent by a larger angle Bending: springbackInitialFinalRifafaiTHow to handle springback:(a) Compensation: the metal is bent by a larger angle(b) Coining the bend:at end of bend cycle, tool exerts large force, dwellscoining: press down hard, wait, release
22 Tooling: similar to punching operation, Deep DrawingTooling: similar to punching operation,Mechanics: similar to bending operationCommon applications: cooking pots, containers, …
24 Body of Olympus E-300 camera Sheet metal parts with combination of operationsBody of Olympus E-300 cameracomponent with multiple bending operationscomponent with punching,bending, drawing operations[image source: dpreview.com]