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Fabrication of Sheet Metal CuttingAbstract

Sheet metal cuttingis a major classification for many different pressworking operations. Cutting operations involve the separation of the metal of the sheet in certain areas. This separation is caused by shearing forces acting on the metal through the edges of the punch and die. Pressworking, a term referencing sheet metal operations in general, involves the working of a sheet between two die. In pressworking, the upper die is called a punch. Sheet and plate generally refers to rolled metal with a high surface area to volume ratio. The difference is that sheet metal is under 1/4 inch (6mm) in thickness, while plate metal is thicker. Most of the sheet metal cutting processes discussed can be performed on both sheet and plate metal, although for many sheet metal operations difficulties will arise with increasing plate thickness. Usually "sheet" and "sheet metal" is also referencing plate.INTRODUCTION

Hydraulic Sheet metal cuttingis a major classification for many different pressworking operations. Cutting operations involve the separation of the metal of the sheet in certain areas. This separation is caused by shearing forces acting on the metal through the edges of the punch and die. Pressworking, a term referencing sheet metal operations in general, involves the working of a sheet between two die. In pressworking, the upper die is called a punch. Sheet and plate generally refers to rolled metal with a high surface area to volume ratio. The difference is that sheet metal is under 1/4 inch (6mm) in thickness, while plate metal is thicker. Most of the sheet metal cutting processes discussed can be performed on both sheet and plate metal, although for many sheet metal operations difficulties will arise with increasing plate thickness. Usually "sheet" and "sheet metal" is also referencing plate.Sheet metal processing The raw material for sheet metal manufacturing processes is the output of the rolling process. Typically, sheets of metal are sold as flat, rectangular sheets of standard size. If the sheets are thin and very long, they may be in the form of rolls. Therefore the first step in any sheet metal process is to cut the correct shape and sized blank from larger sheet.

hydraulic sheet cutter What is Hydraulics ?Hydraulicsis a topic inapplied science and engineering dealing with the mechanical properties of fluids.

On a very basic level Hydraulics is used for the generation, control, and transmission of fluids in order to produce some mechanical work or in general as a part of river engineering.

Cutting Tools

Straight snip - They have straight jaws and used for straight line cutting. Curved snip - They have curved blades for making circular cuts.

Straight snip DemeritsWrinkling and tearing are typical limits to drawing operationsDifferent techniques can be used to overcome these limitationsDraw beadsVertical projections and matching grooves in the die and blank holder Trimming may be used to reach final dimensionMeritsHigh strengthGood dimensional accuracy and surface finishRelatively low costApplicationsRoofingsDuctingsVehicles body buildings like 3 wheelers, 4 wheelers, ships, aircrafts etc.Furnitures, House hold articles and Railway equipmentThe Advantages and Disadvantages of this Hydraulic ArmAdvantages:have many industrial uses.When used in a locomotive format can be of great use in the production and packaging field.The simplicity and easy to repair design makes it really cheap.Disadvantages:The input here is mechanical.Use of electrical circuits can make it much more simpler to operate and have a better control over it which is difficult in purely mechanical design.CONCLUSION This project has met its objective to produce a C-Frame Hydraulic Press and its function is limited to U-Bending. We designed a hydraulic press which costs less than that available in the market. We are very good at what we have done and had fun doing it. Our hydraulic press is useful to do metal forming operations and as it is a 2 tonne capacity press. We can do simple operations like bending, blanking and piercing, which is very useful and helpful to do small works at our college. We chose a simple c-frame press which occupies less space which any one can operate, and manufactured it at 1/3rd of the original cost in the market. We have also done analysis of c-frame of the press. We tested our project by producing a U-bend of sheet metal. Our product was first planned to be a washer but due to cost considerations of die we have limited to bending operation. As our project is based on manufacturing of hydraulic press and U-bending, further modifications can be done and increase its applications.Metal arc weldingIt is a process of joining two metal pieces by melting the edges by an electric arc. The electric arc is produced between two conductors. The electrode is one conductor and the work piece is another conductor. The electrode and the work piece are brought nearer with small air gap. (3mm app.)When current is passed an electric arc is produced between the electrode and the work piece. The work piece and the electrode are melted by the arc. Both molten piece of metal become one. Temperature of arc is about 4000c Electrodes used in arc welding are coated with a flux. This flux produces a gaseous shield around the molten metal. It prevents the reaction of the molten metal with oxygen and nitrogen in the atmosphere. The flux removes the impurities from the molten metal and form a slag. This slag gets deposited over the weld metal. This protects the weld seam from rapid cooling. Fig.1 shows arc welding process.Thank you