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Traditional Manufacturing Processes

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Traditional Manufacturing Processes Casting Forming Sheet metal processing Powder- and Ceramics Processing Plastics processing Cutting Joining Surface treatment – PowerPoint PPT presentation

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Title: Traditional Manufacturing Processes


1
Traditional Manufacturing Processes
Casting
Forming
Sheet metal processing
Powder- and Ceramics Processing
Plastics processing
Cutting
Joining
Surface treatment
2
Sheet Metal Processes
Raw material sheets of metal, rectangular,
large Raw material Processing Rolling
(anisotropic properties)
Processes Shearing Punching Bending Deep
drawing Hydroforming
3
Shearing
A large scissors action, cutting the sheet along
a straight line
Main use to cut large sheet into smaller sizes
for making parts.
4
Shearing
  • Shearing 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 0.125 mm to 6.35
    mm (0.005 to 0.250 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 / Punching
  • Blanking 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 blanking
  • and the product is called blank. If the remaining
    stock is the desired part, the operation is
    called punching.

6
Blanking / Punching
7
Cutting tool is a round/rectangular punch, that
goes through a hole, or die of same shape
8
Punching
Main uses cutting holes in sheets cutting sheet
to required shape
nesting of parts
typical punched part
Exercise how to determine optimal nesting?
9
Bending
Body of Olympus E-300 camera
component with multiple bending operations
component with punching, bending, drawing
operations
image source dpreview.com
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16
Typical bending operations and shapes
17
Sheet metal bending
Planning problem what is the sequence in which
we do the bending operations?
Avoid part-tool, part-part, part-machine
interference
18
Bending mechanics
Bending Planning ? what is the length of blank we
must use?
Ideal case k 0.5
Real cases k 0.33 ( R lt 2T) k 0.5 (R gt
2T)
19
Bending cracking, anisotropic effects, Poisson
effect
Bending ? plastic deformation
Engineering strain in bending e 1/( 1 2R/T)
Bending ? disallow failure (cracking) ? limits on
corner radius bend radius 3T
effect of anisotropic stock
Poisson effect
Exercise how does anisotropic behavior affect
planning?
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21
Bending springback
How 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, dwells
coining press down hard, wait, release
22
Deep Drawing
Tooling similar to punching operation, Mechanics
similar to bending operation
Common applications cooking pots, containers,
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Sheet metal parts with combination of operations
Body of Olympus E-300 camera
component with multiple bending operations
component with punching, bending, drawing
operations
image source dpreview.com
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