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Sheet metal Sheet metal
Group membersGroup members
• M.Salahudin bsme 0111149M.Salahudin bsme 0111149
• M. Aurangzeb bsme 01113122M. Aurangzeb bsme 01113122
SHEET METAL SHEET METAL CHARACERSITICS CHARACERSITICS
• Sheet metal Sheet metal is generally less than 6 is generally less than 6 mm thick and produced by reducing the mm thick and produced by reducing the thickness of the raw material by thickness of the raw material by compressive forces applied through a compressive forces applied through a set of rolls. The process of rolling began set of rolls. The process of rolling began around 1500. Common sheet metals around 1500. Common sheet metals include aluminum alloys, copper, include aluminum alloys, copper, stainless steel, brass, steel, titanium, stainless steel, brass, steel, titanium, zinc alloys. zinc alloys.
FORMABILITY OF SHEET FORMABILITY OF SHEET METAL METAL • Sheet metal fabrication processes can Sheet metal fabrication processes can
mostly be placed into two categories - mostly be placed into two categories - forming and cutting. Forming forming and cutting. Forming processes are those in which the processes are those in which the applied force causes the material to applied force causes the material to plastically deform, but not to fail. Such plastically deform, but not to fail. Such processes are able to bend or stretch processes are able to bend or stretch the sheet into the desired shape the sheet into the desired shape
Formability of Sheet Formability of Sheet MetalMetal
• Many types of metals are suitable for sheet Many types of metals are suitable for sheet metal working depending on their formability:metal working depending on their formability:
• Aluminum, copper and their alloys - generally Aluminum, copper and their alloys - generally excellentexcellent
• Mild steel and stainless steel generally - Mild steel and stainless steel generally - generally fair to excellentgenerally fair to excellent
• Nickel and magnesium - generally fair to goodNickel and magnesium - generally fair to good
BENDING OF SHEET METAL BENDING OF SHEET METAL AND PLATE AND PLATE
• One of the most common One of the most common metalworking operation is bending metalworking operation is bending
COMMON BENDING COMMON BENDING OPERATION OPERATION
• Press break formingPress break forming
• Sheet metal can bent with simple fixture Sheet metal can bent with simple fixture called press.this machine use long dies in called press.this machine use long dies in a mechanical and it is suitable for small a mechanical and it is suitable for small production .the tooling is simple and production .the tooling is simple and adoptable to wide variety of shapes and adoptable to wide variety of shapes and the process can be easily automated die the process can be easily automated die material for most application are carbon material for most application are carbon steel or grey iron steel or grey iron
BEADING BEADING
• The edge of the sheet is bent into The edge of the sheet is bent into cavity of a die .beading also improve cavity of a die .beading also improve the appearance of the part and the appearance of the part and eliminate sharp edge which may be eliminate sharp edge which may be safty hazard safty hazard
FLANGINGFLANGING
• Bending the edge of sheet metal Bending the edge of sheet metal typically to 90.in shrink flanging the typically to 90.in shrink flanging the flnge periphery is subjected to flnge periphery is subjected to compressive stress if excessive compressive stress if excessive cause to wrinkle.in streach flanging cause to wrinkle.in streach flanging the flange is subjected to tensile the flange is subjected to tensile stress if excessive cause to cracking stress if excessive cause to cracking and tearing at the adge and tearing at the adge
HEAMMING HEAMMING
• In hemming process the edge of the In hemming process the edge of the sheet is folded itself heeming sheet is folded itself heeming increase the stiffness of the part increase the stiffness of the part improve its appeance and eliminate improve its appeance and eliminate its sharp edges its sharp edges
ROLL FORMING ROLL FORMING
• This process is used for bending This process is used for bending continues length sheet metal and for continues length sheet metal and for large production run salso called cold large production run salso called cold roll forming the metal strip bent in roll forming the metal strip bent in this operation is passed through the this operation is passed through the series of rolls typical product are series of rolls typical product are frames panels .frames panels .
BLANKING BLANKING
•Blanking is a cutting process in Blanking is a cutting process in which a piece of sheet metal is which a piece of sheet metal is removed from a larger piece of removed from a larger piece of stock by applying a great enough stock by applying a great enough shearing force. In this process, shearing force. In this process, the piece removed, called the the piece removed, called the blankblank
Laser cuttingproduces part shapes by cutting sheet
material using an intense laser beam. In CNC laser cutting a beam of high-density light energy is focused through a tiny hole in a nozzle. When this beam strikes the surface of the work piece, the material of the work piece is vaporized
CNC plasma cuttingCNC plasma cutting
• is a process of cutting 2D shapes is a process of cutting 2D shapes from from sheet metal using a high using a high temperature, high velocity stream of temperature, high velocity stream of ionized gasionized gas
CNC waterjet cuttingCNC waterjet cutting
• is a process that produces shapes by is a process that produces shapes by cutting sheet material using a high cutting sheet material using a high pressure stream of water containing pressure stream of water containing abrasive(finishing) particles abrasive(finishing) particles
Photo chemical millingPhoto chemical milling
• is a process that produces 2D part is a process that produces 2D part shapes by creating a chemical resist shapes by creating a chemical resist mask on the surface of sheet metal mask on the surface of sheet metal and chemically dissolving material and chemically dissolving material from unmasked areasfrom unmasked areas
Band sawingBand sawing
• creates rough cuts by applying a creates rough cuts by applying a continuous-loop saw blade to the continuous-loop saw blade to the material being cut. Band sawing is material being cut. Band sawing is often a first step to other machining often a first step to other machining processes processes
ShearingShearing,,
• on a conventional straight shears, on a conventional straight shears, makes straight cuts in material of makes straight cuts in material of limited thickness using a scissors-like limited thickness using a scissors-like action action
CNC turret punchingCNC turret punching
• creates shapes in sheet material by creates shapes in sheet material by successively punching a series of successively punching a series of basic shapes such as circles and basic shapes such as circles and rectangles. The basic shapes are rectangles. The basic shapes are selected from a rotating turret under selected from a rotating turret under CNC controlCNC control
Wire EDM cuttingWire EDM cutting,,
• also known as also known as electrical discharge electrical discharge machiningmachining, is a process that uses an , is a process that uses an electrically energized thin wire to slice electrically energized thin wire to slice through metal. Wire EDM cutting uses through metal. Wire EDM cutting uses rapid, controlled, repetitive spark rapid, controlled, repetitive spark discharges from the wire to the discharges from the wire to the workpiece, thereby eroding the metal workpiece, thereby eroding the metal away. The workpiece must be electrically away. The workpiece must be electrically conductive. conductive.
• Gear cut by Wire EDMGear cut by Wire EDM
• CNC millingCNC milling is a cutting process in is a cutting process in which material is removed from a which material is removed from a block by a rotating tool. block by a rotating tool.
CountersinkingCountersinking
• creates a V shaped recess near the creates a V shaped recess near the surface of a hole.surface of a hole.
• Countersinking is often used to Countersinking is often used to recess a flat head screw or to recess a flat head screw or to chamfer hole edges. The process of chamfer hole edges. The process of countersinking is usually applied to countersinking is usually applied to round holes. round holes.
Countersink tool
Roll formingRoll forming
The process is performed on a roll forming The process is performed on a roll forming line in which the sheet metal stock is fed line in which the sheet metal stock is fed through a series of roll stations. Each through a series of roll stations. Each station has a roller, referred to as a roller station has a roller, referred to as a roller die, positioned on both sides of the sheet. die, positioned on both sides of the sheet. The shape and size of the roller die may be The shape and size of the roller die may be unique to that station, or several identical unique to that station, or several identical roller dies may be used in different roller dies may be used in different positions. The roller dies may be above and positions. The roller dies may be above and below the sheet, along the sides, at an below the sheet, along the sides, at an angle, angle,
Fine blankingFine blanking• IT is a shearing process that IT is a shearing process that
produces parts with a higher quality produces parts with a higher quality edge than conventional blanking. In edge than conventional blanking. In fine blanking pressure is applied to fine blanking pressure is applied to both sides of the part during the both sides of the part during the shearing action. The image shows a shearing action. The image shows a part made by conventional blanking part made by conventional blanking (top) and fine blanking (bottom)(top) and fine blanking (bottom)
Fine Blanking Machine
Lueders Bands
SPINNINGSPINNING
• Spinning, sometimes called spin forming, is a metal Spinning, sometimes called spin forming, is a metal forming process used to form cylindrical parts by forming process used to form cylindrical parts by rotating a piece of sheet metal while forces are rotating a piece of sheet metal while forces are applied to one side. A sheet metal disc is rotated at applied to one side. A sheet metal disc is rotated at high speeds while rollers press the sheet against a high speeds while rollers press the sheet against a tool, called a mandrel, to form the shape of the tool, called a mandrel, to form the shape of the desired part. Spun metal parts have a rotationally desired part. Spun metal parts have a rotationally symmetric, hollow shape, such as a cylinder, cone, symmetric, hollow shape, such as a cylinder, cone, or hemisphere. Examples include cookware, or hemisphere. Examples include cookware, hubcaps, satellite dishes, rocket nose cones, and hubcaps, satellite dishes, rocket nose cones, and musical instrumentsmusical instruments
• ,good surface finish low tooling cost but labour ,good surface finish low tooling cost but labour unless automated.unless automated.
BlankingBlanking
• The blanking process requires a blanking The blanking process requires a blanking press, sheet metal stock, blanking punch, press, sheet metal stock, blanking punch, and blanking die. The sheet metal stock is and blanking die. The sheet metal stock is placed over the die in the blanking press. placed over the die in the blanking press. The hydraulic press drives the punch The hydraulic press drives the punch downward at high speed into the sheet. downward at high speed into the sheet. When the punch impacts the sheet, the When the punch impacts the sheet, the metal in this clearance quickly bends and metal in this clearance quickly bends and then fractures. The blank which has been then fractures. The blank which has been sheared from the stock now falls freely into sheared from the stock now falls freely into the gap in the die. the gap in the die.
DEEP DRAWINGDEEP DRAWING
• Deep drawing is a metal forming process in which Deep drawing is a metal forming process in which sheet metal is stretched into the desired part sheet metal is stretched into the desired part shape. A tool pushes downward on the sheet shape. A tool pushes downward on the sheet metal, forcing it into a die cavity in the shape of metal, forcing it into a die cavity in the shape of the desired part. The tensile forces applied to the the desired part. The tensile forces applied to the sheet cause it to plastically deform into a cup-sheet cause it to plastically deform into a cup-shaped part. Deep drawing is most effective with shaped part. Deep drawing is most effective with ductile metals, such as aluminum, brass, copper, ductile metals, such as aluminum, brass, copper, and mild steel. Examples of parts formed with and mild steel. Examples of parts formed with deep drawing include automotive bodies and fuel deep drawing include automotive bodies and fuel tanks, cans, cups, kitchen sinks, and pots and tanks, cans, cups, kitchen sinks, and pots and pans.pans.
Deep drawingDeep drawing
• The deep drawing process requires a blank, blank The deep drawing process requires a blank, blank holder, punch, and die. The blank is a piece of sheet holder, punch, and die. The blank is a piece of sheet metal, typically a disc or rectangle, which is pre-cut metal, typically a disc or rectangle, which is pre-cut from stock material and will be formed into the part. from stock material and will be formed into the part. The blank is clamped down by the blank holder over The blank is clamped down by the blank holder over the die, which has a cavity in the external shape of the die, which has a cavity in the external shape of the part. A tool called a punch moves downward the part. A tool called a punch moves downward into the blank and draws, or stretches, the material into the blank and draws, or stretches, the material into the die cavity. The movement of the punch is into the die cavity. The movement of the punch is usually hydraulically powered to apply enough force usually hydraulically powered to apply enough force to the blank. Both the die and punch experience to the blank. Both the die and punch experience wear from the forces applied to the sheet metal and wear from the forces applied to the sheet metal and are therefore made from tool steel or carbon steel.are therefore made from tool steel or carbon steel.
Can makingCan making
BlankingBlanking
• Deep drawingDeep drawing
• Re drawingRe drawing
• IroningIroning
• DoomingDooming
• NeckingNecking
• sceamingsceaming
Strech FORMING Strech FORMING
• Stretch forming is a metal forming process in Stretch forming is a metal forming process in which a piece of sheet metal is stretched and which a piece of sheet metal is stretched and bent simultaneously over a die in order to bent simultaneously over a die in order to form large contoured parts. Stretch forming form large contoured parts. Stretch forming is performed on a stretch press, in which a is performed on a stretch press, in which a piece of sheet metal is securely gripped piece of sheet metal is securely gripped along its edges by gripping jaws. The along its edges by gripping jaws. The gripping jaws are each attached to a carriage gripping jaws are each attached to a carriage that is pulled by pneumatic or hydraulic force that is pulled by pneumatic or hydraulic force to stretch the sheetto stretch the sheet
Stretch forming Stretch forming
• Stretch formed parts are typically large and Stretch formed parts are typically large and possess large radius bends. The shapes that possess large radius bends. The shapes that can be produced vary from a simple curved can be produced vary from a simple curved surface to complex non-uniform cross surface to complex non-uniform cross sections. Stretch forming is capable of sections. Stretch forming is capable of shaping parts with very high accuracy and shaping parts with very high accuracy and smooth surfaces. Ductile materials are smooth surfaces. Ductile materials are preferable, the most commonly used being preferable, the most commonly used being aluminum, steel, and titaniumaluminum, steel, and titanium
SHEARINGSHEARING
• The shearing process is performed on a shear The shearing process is performed on a shear machine, often called a squaring shear or power machine, often called a squaring shear or power shear, that can be operated manually (by hand or shear, that can be operated manually (by hand or foot) or by hydraulic, pneumatic, or electric foot) or by hydraulic, pneumatic, or electric power. A typical shear machine includes a table power. A typical shear machine includes a table with support arms to hold the sheet, stops or with support arms to hold the sheet, stops or guides to secure the sheet, upper and lower guides to secure the sheet, upper and lower straight-edge blades, and a gauging device to straight-edge blades, and a gauging device to precisely position the sheet. The sheet is placed precisely position the sheet. The sheet is placed between the upper and lower blade, which are between the upper and lower blade, which are then forced together against the sheet, cutting then forced together against the sheet, cutting the material. the material.
PUNCHINGPUNCHING
• Punching is a cutting process in which Punching is a cutting process in which material is removed from a piece of material is removed from a piece of sheet metal by applying a great sheet metal by applying a great enough shearing force. Punching is enough shearing force. Punching is very similar to blanking except that the very similar to blanking except that the removed material, called the slug, removed material, called the slug, Punching can be used to produce holes Punching can be used to produce holes and cutouts of various shapes and sizes and cutouts of various shapes and sizes ..
Tube BendingTube Bending
• Bending and forming tubes and Bending and forming tubes and holllow sections. They require special holllow sections. They require special tooling to avoid buckling and folding.tooling to avoid buckling and folding.
Sheet Metal ApplicationsSheet Metal Applications • Sheet metal is widely used for numerous industrial Sheet metal is widely used for numerous industrial
and non-industrial applications including:and non-industrial applications including:• Aircraft:Aircraft: Fuselages, wings, body panels, trim Fuselages, wings, body panels, trim
parts, etc. parts, etc. • AutomotiveAutomotive: body panels, bumpers, doors, : body panels, bumpers, doors,
chassis, trim parts, brackets etc. chassis, trim parts, brackets etc. • Construction:Construction: roofing, home building and roofing, home building and
structural applications. structural applications. • Other applications:Other applications: appliances, food and appliances, food and
beverage containers, boilers, kitchen equipment, beverage containers, boilers, kitchen equipment, office equipment etc. office equipment etc.
chassis
Bracket
