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SheetMetal Forming Processes

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Metal-Forming Process for Food and Beverage Containers ... rivets: (a) solid, (b) tubular, (c) split (or bifurcated), and (d) compression. ... – PowerPoint PPT presentation

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Title: SheetMetal Forming Processes


1
Sheet-Metal Forming Processes
2
Sheet-Metal Forming Processes
3
Aluminum Two-Piece Beverage Cans
  • FIGURE 7.77 Aluminum two-piece beverage cans.
    Note the fine surface finish. Source Courtesy of
    J. E. Wang, Texas AM Univerity.

4
Metal-Forming Process for Food and Beverage
Containers
  • FIGURE 7.76 The metal-forming process used to
    manufacture two-piece beverage cans.

5
Punching, Blanking and Shearing Operations
  • FIGURE 7.8 (a) Punching (piercing) and
    blanking. (b) Examples of various shearing
    operations on sheet metal.

6
Efficient Nesting of Blanks
  • FIGURE 7.69 Efficient nesting of parts for
    optimum material utilization in blanking. Source
    Society of Manufacturing Engineers.

7
Shearing
  • FIGURE 7.4 Schematic illustration of the
    shearing process with a punch and die. This
    process with a punch and die. This process is a
    common method of producing various openings in
    sheet metals.

8
Progressive Dies
  • FIGURE 7.13 (a) Schematic illustration of the
    making of a washer in a progressive die. (b)
    Forming of the top piece of an aerosol spray can
    in a progressive die. Note that the part is
    attached to the strip until the last operation is
    completed.

9
The Effect of Bending On Too Tight A Radius
10
Minimum Bend Radii
  • TABLE 7.2 Minimum bend radii for various
    materials at room temperature.

11
Common Die-Bending Operations
  • FIGURE 7.22 Common die-bending operations,
    showing the die-opening dimension W used in
    calculating bending forces. See Eq,(7.11).

12
Presses
  • Solid Gap Frame(150 tons)
  • OBI
  • Adjustable bed frames
  • Turret Presses

13
PressBrake 30 feet, 1250 ton Niagara Machine
and Tool Works
14
Bending Operations In a Press Brake
  • FIGURE 7.23 Schematic illustration of various
    bending operations in a press brake.

15
Bead Forming
  • FIGURE 7.25 (a) Bead forming with a single die.
    (b) Bead forming with two dies in a press brake.

16
Bending
  • FIGURE 7.15 (a) Bending terminology. The bend
    radius is measured to the inner surface of the
    bend. Note that the length of the bend is the
    width of the sheet. Also note that the bend angle
    and the bend radius (sharpness of the bend) are
    two different variables. (b) Relationship between
    the ratio of bend radius to sheet thickness and
    tensile reduction of area for various materials.
    Note that sheet metal with a reduction of area of
    about 50 can be bent and flattened over itself
    without crackling. Source After J. Datsko and C.
    T. Yang.

17
Bend Allowance
  • Unless specified otherwise, r t
  • q positive included angle from flat
  • k is a material constant

t
18
Material is 0.050 Alum. Measurements are O.D.
Holes (6) are 3/32 dia, 1/4 from edge
3.600
2.050
1.25
.550
4.570
19
Depth of Notch ________
.25
20
Bend Allowance Calculation Methods
Outside Width
Height
r usually t
r
Flat Length 2(Height-r-t) Outside Width
2(tr) 2(Bend Allowance)
21
Bend Allowance Calculation
  • Determine The Bend Points

Bend Point Height-r-t1/2Bend Allowance
22
Depth of Notch Height-t-rBend Allowance Need
To Leave Room For Over Bend
Flat Length 2(Height-r-t) Outside Width
2(tr) 2(Bend Allowance)
Bend Point
Flat Length
.25
Bend Point Height-r-t1/2Bend Allowance
23
Deep-drawing Process
  • FIGURE 7.50 (a) Schematic illustration of the
    deep-drawing process. This procedure is the first
    step in the basic process by which aluminum
    beverage cans are produced today. The stripper
    ring facilitates the removal of the formed cup
    from the punch. (b) Variables in deep drawing of
    a cylindrical cup. Only the punch force in this
    illustration is a dependent variable all others
    are independent variables, including the
    blankholder force.

24
Explosive Forming Process
  • FIGURE 7.42 Schematic illustration of the
    explosive-forming process. Although explosives
    are generally used for destructive purposes,
    their energy can be controlled and employed in
    forming large parts that would otherwise be
    difficult or expensive to produce by other
    methods.

25
Roll-Forming Process
  • FIGURE 7.27 The roll-forming process.
  • FIGURE 7.28 Stages in roll forming of a
    sheet-metal door frame. In Stage 6, the rolls may
    be shaped as in A or B. Source G. Oehler.

26
Fastening
  • Riveting / Stitching
  • Seaming /Crimping
  • Welding Processes

27
Examples of Rivets and Stitching
  • FIGURE 12.48 Examples of rivets (a) solid, (b)
    tubular, (c) split (or bifurcated), and (d)
    compression.
  • FIGURE 12.49 Examples of metal stitching.

28
Designs Guidelines for Riveting
  • FIGURE 12.58 Design guidelines for riveting.
    Source J. G. Bralla.

29
Double-Lock Seam and Crimping
  • FIGURE 12.50 Stages in forming a double-lock
    seam.
  • FIGURE 12.51 Two examples of mechanical joining
    by crimping.

30
Home Work
  • Read
  • http//www.thefabricator.com/ToolandDie/ToolandDie
    _Article.cfm?ID1747
  • http//en.wikipedia.org/wiki/Sheet_metalCutting
  • Do Sheet Metal homework located on Web CT, Print
    complete turn in next lecture.
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