Typically, sheets of metal are sold as flat, rectangular sheets of standard size. Sheet metal operations other sheet metal forming processes. Manufacturing processes i nptel online videos, courses. Using numerical control shearing machine for net size blanking, this is specially. The tubes are attached to tube sheet with two or more grooves in the tube sheet wall by tube rolling the tube. Boothroyd et al, design for sheet metal working gm, a machinepaced line flow process reif, steps to building a sheet metal chassis for your 2. The industry refers to polishing as the process, which uses abrasive belt finishing. Definitions and classification of metal forming processes. Pdf analysis of sheet metal extrusion process using finite. Tig welding has become a popular choice of welding processes when high quality, precision welding is required.
Process definition gas metal arc welding gmaw, by definition, is an arc welding process which produces the coalescence of metals by heating them with an arc between a continuously fed filler. Thus the metal gets compressed very severely, causing shear stress. Sheet metal, manufacturing, design formula and calculations. In fact as the metal or alloys gets progressively strain hardened, more and more force is required to cause further plastic deformation.
Forming nptel web course free ebook download as pdf file. These manufacturing process som study notes will help you to get conceptual deeply knowledge about it. Process information model for sheet metal operations. In low carbon steel sheet metal, the minimum radius of a bend should be onehalf the material thickness or 0. In cold working process the strain hardening which occurs as a result of mechanical working, does not get relieved. One is bulk forming and the other is sheet metal forming. Sheet metal forming processes sheet metal processes can be broken down into two major classifications and one minor. Pickling is a chemical process whereby steel is run through a progressive series of tanks. The following are to links of sheet metal design resources, tools, articles and other useful data. The forming analysis and the comparison of the data with the flc provide for a reliable assessment of sheet metal forming processes. Knowing the final strain in the forming process, one can calculate flow stress using above equation.
This lecture describes the fundamentals of sheet metal operations including working principle, mechanisms involved and various processes etc. Shearing not a forming process but a cutting process. Process design is the ensemble of operations leading from the design geometry to. Sheet metal, manufacturing, design equations and calculations manufacturing knowledge menu sheet metal knowledge. Sheet metalworkingforming on metal sheets, strips, and coils. Fabrication and manufacturing basics batch processes fabrication time independent of design complexity standard process customization by masks each mask defines geometry on one layer. Fundamental concepts of metal forming technology nptel. We are here to provides you the best study notes from best.
Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. Unit 9 computer aided process computer aided process. Mechanical engineering manufacturing processes i nptel. Welding is most commonly associated with metal parts, but the process is also used for joining plastics. Process description and analysis of forging, rolling, extrusion, drawing and. Metal forming processes, also known as mechanical working processes, are primary. Welding is a relatively new process historical note. Stretch forming is a metal forming process in which a piece of sheet metal is. In such cases, an average flow stress is determined from the flow curve. Using numerical control shearing machine for net size blanking, this is specially applied in piece processing with lower demand, most of the process engineer use shearing machine for blanking to reduce the processing cost. The first one is sheet metal cutting, second one is sheet metal bending or forming and the last one is known as deep drawing. Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section.
In this process, a consumable electrode consisting of a filler metal rod which is coated with chemicals that provide flux and shielding, is used. Generally the filler metal has chemical composition very close to base metal. Process information model, process parameters, sheet metal operation. May 07, 2017 mainly sheet metal process can be divided into three types. Following hot working, steel goes through a pickling process. Cost considerations 2019 energy requirements 2019 kalpakjian pp. Sheet metal parts are some of the most important semifinished products.
A few among the most common applications of sheet metal parts are as automobile and aircraft panels, housings, cabinets. This lecture describes the fundamentals of sheet metal operations including working principle, mechanisms involved and various. The process uses shielding from an externally supplied gas to protect the molten weld pool. Design for manufacturability sheet metal guidelines. Jul 28, 2009 lecture series on manufacturing processes i by prof.
Sheet metal characteristics elongation the capability of the sheet metal to stretch without necking and failure. Lecture series on manufacturing processes i by prof. Sheet metal operations i lecture 38 sheet metal operations ii lecture 39 powder metallurgy forming i lecture 40 powder metallurgy forming ii. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses.
Chandramouli associate deanresearch sastra university, thanjavur6 401. Metal forming processes full notes ebook free download pdf. The cloth buff holds or carries the compound, while the compound does the cutting. Luders bands can be eliminated by coldrolling the thickness by 0. In low carbon steel sheet metal, the minimum radius of a bend should be one. The tubes are attached to tube sheet with two or more grooves in the tube sheet wall by tube rolling the tube metal is forced to move into the grooves forming an excellent tight seal. Avoid large sheet metal parts with small bent flanges. Sep 03, 2017 this lecture describes the fundamentals of sheet metal operations including working principle, mechanisms involved and various processes etc. Layout the stock strip, preferably using at least three part templates. Therefore the first step in any sheet metal process is to cut the correct shape and sized blankfrom larger sheet.
Coating consists of powdered cellulose cotton and wood. The tubes can be fixed with the tube sheet using ferrule and a soft metal packing ring. Passivation room temperature process, duration1520 minutes, forsealing pores of sheet metal surface for obtaining maximum corrosion resistance over phosphate coating by decxylite solution oven drying 150 deg c process, duration1020 minutes, for drying sheet metal parts by hot air. Passivation room temperature process, duration1520 minutes, forsealing pores of sheet metal surface for obtaining maximum corrosion resistance. Metal forming is the main method of making metal products and semifinished products. Yieldpoint elongation lueders bands on lowcarbon steels and almg alloys. Progress in blankholder systems in the pulsating blankholder system the blankholder is subjected to a vibratory pulsating force. Process definition gas metal arc welding gmaw, by definition, is an arc welding process which produces the coalescence of metals by heating them with an arc between a continuously fed filler metal electrode and the work. Reinforced plastics, metalmatrix and ceramicsmatrix composites, and honeycomb structures nanomaterials, shapememory alloys, metal foams, amorphous alloys, super conductors. Mainly sheet metal process can be divided into three types. In this article we mainly focus on sheet metal cutting operations and other two we will discuss into upcoming articles. 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. Press working operations or sheet metal operations blanking. More than 90% of smelted metal is processed by different methods of metal forming.
Sheet metal forming processes sheet metal processes can be broken down into two major classifications and one minor classification shearing processes processes which apply shearing forces to cut, fracture, or separate the material. In this operation, forming of a flat metal sheet into a hollow or concave shape like a cup, is performed by stretching the metal in some regions. Drawing forming a sheet into a hollow or concave shape. Sheetmetal characteristics elongation the capability of the sheet metal to stretch without necking and failure.
Tig welding is a commonly used high quality welding process. In sheet metal forming practice, we distinguish five basic modes of. Different sheet metal operations with diagrams guide by tips. Typically, sheets of metal are sold as flat, rectangular. Plastic properties of metals are used during the process of metal forming. Mar 06, 20 sheet metalworkingforming on metal sheets, strips, and coils. Fabrication and manufacturing basics batch processes fabrication time independent of design complexity standard process customization by masks each mask defines geometry on one layer lowerlevel masks define transistors higherlevel masks define wiring silicon is neat stuff oxide protects things from impurities. 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. Design for manufacturability sheet metal guidelines bends for the ease of manufacturing, multiple bends on the same plane should occur in the same direction. 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. Introduction to buffing buffing is the process used to shine metal, wood, or composites using a cloth wheel impregnated with cutting compounds or rouges. Bending straining of a metal sheet to form an angle bend.
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