Nptel mechanical engineering forming joint initiative of iits and iisc. It uniformly thins the workpiece in a specific area. The reliability of simulation depends on the accuracy of. 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. High energy rate forming of sheet metal manufacturing process. Metal forming processes full notes ebook free download pdf. Lecture series on manufacturing processes i by prof. Type of forming process rolling, forging, sheet metal drawing, etc. Sep 29, 2015 comparison of metal forming processescomparison of metal forming processes 34. Recent advances in metal forming processes authorstream. The stripper ring facilitates the removal of the formed cup from the punch.
Two electrodes, with a wire connecting them, are submersed in liquid. Where possible, the limits governing each process are identi. Metal forming is the main method of making metal products and semifinished products. It may be necessary to model each of them gravity fall. Nptel syllabus manufacturing processes i video course metal forming elastic and plastic deformation. Sheet metal forming massachusetts institute of technology. They include a very wide range of consumer and industrial products, such as beverage. Design for manufacturability sheet metal guidelines bends for the ease of manufacturing, multiple bends on the same plane should occur in the same direction. Sheet metal forming processes and applications asm. Difference between bulk deformation and sheet metal forming. In sheet metal working, the metal being processed will have a high surface area to volume ratio. More than 90% of smelted metal is processed by different methods of metal forming.
Finite element analysis of sheet metal forming process 62 figure 5. The key difference between bulk deformation and sheet metal forming is that in bulk deformation, the work parts have a low area to volume ratio whereas, in sheet metal. Metal forming processes, also known as mechanical working processes, are primary shaping. The reliability of simulation depends on the accuracy of the. Materials which do not become brittle at higher strain rates alone can be explosive formed. In this article we mainly focus on sheet metal cutting operations and other two we will discuss into upcoming articles. Self reading for your interestself reading for your interest defects in metal forming. Design for manufacturability sheet metal guidelines.
A sheet formed part is usually obtained through a number of operation phases. The following is a brief overview of the major metal forming processes that will be covered in detail later. Sheet metal work stock, used for sheet metal processes, is usually formed by rolling and comes in coils. The aim of the paper is to explain the extraction of process parameters and their values for sheet metal operation which is the main component of the process information model and is required for automation of the manufacturing process. Bending, stretching and drawing of simple shapes are analysed, as are certain processes for forming thinwalled tubing. Principles of metal forming technology course swayam. Transverse sheet stretch forming press fett up to 12 independently controlled axes allow for the forming of leading edge and fuselage. Sheetmetal characteristics elongation the capability of the sheet metal to stretch without necking and failure. Mechanical engineering manufacturing processes i nptel. Metal forming is possible in case of such metals or alloys which are. Self reading for your interestself reading for your interest defects in metal forming processesdefects in metal forming processes and their remedies. 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.
Sheet metal forming involves a wide range of processes that manufacture parts for a vast amount of purposes, both seen and unseen. One is bulk forming and the other is sheet metal forming. This manufacturing process uses the energy from the combustion of. Drawing is a sheet metal forming operation used to make cupshaped, boxshaped, or other complexcurved and concave parts. Deepdrawing a schematic illustration of the deepdrawing process on a circular sheetmetal blank. Sheet metal operations other sheet metal forming processes. This practical and comprehensive reference gives the latest developments on the design of sheet forming operations, equipment, tooling, and process modeling. Reprint with revisions and sheet metal forming processes. The surface areatovolume ratio of the starting metal is relatively high. Therefore the first step in any sheet metal process is to cut the correct shape and sized blankfrom larger sheet.
The first one is sheet metal cutting, second one is sheet metal bending or forming and the last one is known as deep. Mechanics of sheet metal forming college of engineering. Classification of basic sheet forming processes bending deep drawing shearing. The process involves stretching the sheet to a calculated yield point and forming it over a tool. It is used to produce a uniform wall thickness part with a high heighttodiameter ratio.
Yokohama, japan, 7th 9th july 2014 process information model for sheet metal operations ravi kumar gupta1, pothala sreenu2, alain bernard3, florent laroche4, 1, 2 mechanical. The forming analysis and the comparison of the data with the flc provide for a reliable assessment of sheet metal forming processes. Jul 27, 2009 lecture series on manufacturing processes i by prof. Practically all metals, which are not used in cast form are reduced to some standard shapes for subsequent processing. Forming nptel web course free ebook download as pdf file. What are the requirements for superplastic forming. This is a commonly used manufacturing process that helps in manufacturing the parts for tons of known and unknown purposes.
Nptel mechanical engineering forming joint initiative of iits and iisc funded by mhrd page 3 of. Manufacturing companies producing metals supply metals in form of ingots which are obtained by casting liquid metal into a square cross section. Jul 22, 2009 lecture series on manufacturing processes i by prof. Friction is the main phenomenon that has a huge influence on the flow behavior of deformed material in sheet metal forming operations. Under the action of such forces, the shape and size of metal piece undergo a change. Other sheet metal forming operationsquiz questions. Typically, metal forming processes can be classified into two broad groups. Hot and cold working processes rolling, forging, extrusion, swaging, wire and tube drawing. Rolling is a metal forming process that deforms the work by the use of rolls. Bulk deformation and sheet metal forming are important deformation process for metal workpieces. Such backpressure avoids cavitation of the sheet metal. Plastic properties of metals are used during the process of metal forming. Nptel provides elearning through online web and video courses various streams. Fundamental concepts of metal forming technology nptel.
Welding is a metal joining process in which two or more parts are joined or coalesced at. Plastic sheet is heated to a sag point softened, but not melted heated sheet placed over a roomtemperature mold and forced against it by vacuum pressure stretch forming process material thickness variations advertising signs, refrigerator liners, appliance housings, shower stalls, packaging. Understanding basic principles of metal forming and further being applied by engineers. Then the problem is the time required will also be high, then and another problem is the spring back problem. The first one is sheet metal cutting, second one is sheet metal bending or forming and the last one is known as deep drawing. Joining of materials joining includes welding, brazing, soldering, adhesive bonding of materials. The following is a brief overview of the major metal forming processes that will be covered in.
Sheet metal refers to metal that has a high surface area to volume ratio. Sheet metal is metal formed by an industrial process into thin, flat pieces. Aug 09, 2019 summary bulk deformation vs sheet metal forming. This procedure can form simple tubes or it can form intricate hollow tubes as shown in the following figure.
May 07, 2017 mainly sheet metal process can be divided into three types. Avoid large sheet metal parts with small bent flanges. Luders bands can be eliminated by coldrolling the thickness by 0. Introduction to rolling processes introduction rolled productsrolling mills typical rolling processes quiz questions. A sheet formed part is usually obtained through a number of operation phases final surface. Process design is the ensemble of operations leading from the design geometry to. Progress in blankholder systems in the pulsating blankholder system the blankholder is subjected to a vibratory pulsating force. Sheet metal is one of the fundamental forms used in metalworking, and it can be cut and bent into a variety of. Finite element analysis of sheet metal forming process. Sheet metal forming processes mustansiriyah university.
Comparison of metal forming processescomparison of metal forming processes 34. Fundamentals of metal forming overview of metal forming material behavior in metal forming temperature in metal forming. Sheet metal forming processes sheet metal procedural. Ironing is a sheet metal working or sheet metal forming process. Sep 25, 2011 fundamentals of metal forming overview of metal forming material behavior in metal forming temperature in metal forming. Yieldpoint elongation lueders bands on lowcarbon steels and almg alloys.
Hot working and cold working operatio slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. There are several distinct mechanisms of laser forming depending on the process setup, for the temperature gradient mechanism tgm above, using a small spot size and fast traverse speed, the thermal expansion of the upper surface of sheet metal would be hindered by the surrounding material, which would result in an upsetting of the heated. It is a narrow boundary that separates the fusion zone from heat affected zone. Press working operations or sheet metal operations blanking. There are several distinct mechanisms of laser forming depending on the process setup, for the temperature gradient mechanism tgm above, using a small spot size and fast. Sheet metal forming involves forming and cutting operations performed on metal sheets, strips, and coils. Deepdrawing a schematic illustration of the deepdrawing process on a circular sheet metal blank.
Numerical simulation of sheet metal forming processes, such as the stamping process, plays an important role in the design phase 1. The process involves stretching the sheet to a calculated yield point and. Sheet metal operations other sheet metal forming processes nptel. Process information model for sheet metal operations. This is very much associated with all the conventional forming, most of the conventional forming processes applied to sheet metal forming.
Sheet metal forming methods are one of the most popular. In low carbon steel sheet metal, the minimum radius of a bend should be onehalf the material thickness or 0. Electrohydraulic forming, also called electric discharge forming, is a unique high energy forming process for sheet metal. Mainly sheet metal process can be divided into three types.
Google books result metal formingprocesses and analysis by b. The surface areatovolume ratio of the starting metal is relatively. Argon gas is used for pressurizing the sheet metal on one side, whereas on the other side, a low pressure of argon gas is maintained. This zone consists of a thin band of base metal that was partially melted during the welding process but. Different sheet metal operations with diagrams guide by tips. Definitions and classification of metal forming processes. Plastic sheet is heated to a sag point softened, but not melted heated sheet placed over a roomtemperature mold and forced against it by vacuum pressure stretch forming process. Fundamentals of metal forming overview of metal forming material behavior in metal forming. The key difference between bulk deformation and sheet metal forming is that in bulk deformation, the work parts have a low area to volume ratio whereas, in sheet metal forming, the area to volume. Metal forming processes, also known as mechanical working processes, are primary shaping processes in which a mass of metal or alloy is subjected to mechanical forces. Bending is one very common sheet metal forming operation used not only to form shapes like. Forming sheet stretch forming is a fast, economical, and accurate way to form a large panel from a metal sheet. This manufacturing process uses the energy from the combustion of a thin metal wire.
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