Project on Sheet metal Technology

Project Prepared by Pallav Gupta, Himanshu Jain

Contents
1. Introduction 3. Technology 2. Material Science and Engineering applications 4 Sheet Metal Operations 5 Sheet Metal Machines A Shearing Machine B Presses C Fabrication D Surface Preparation and Surface Coating. 5 Manufacturing of Pipe Holding Clamp

S.No . 1 2 Process Flow Diagram Process Sheet

Description

3
4 5

Control Plan
FMEA Inspection Standard

6 Costing

Introduction
Sheet Metal technology is basically a metal working technology which was developed way back in ancient times with the development of the metals. This technology has wide spread applications right from Automobile to Watch to building construction to electronics.

Material

All the present in the universe have Physical and Chemical properties which distinguishes the characteristics of a metal and thus its utilization for application. Following are the properties of the metal Ductility, Malleability, Brittleness, Elasticity, Plasticity, Hardness, Fatigue or Endurance Strength, Tensile Strength Yield Strength Toughness Stiffness

Properties of Metal
Ductility - It is the physical property of metal by virtue of which it can be converted into a wire. Malleability- It is defined as the ability of metal to be hammered into thin sheets. Brittleness- it is the tendency of a metal to fracture before any visible plastic deformation or without plastic deformation. Elasticity- it is the physical property of material to regain its original shape when it is resumed from stress under elastic limit. Plasticity- it is the permanent deformation of material and it occurs when material is under stress higher than elastic limit. Hardness- it is defined as the resistance of material to deformation. Endurance Strength-it is defined as the maximum safe stress or load that a component can bear without fatigue failure under infinite no. of cycles. Tensile Strength- It is defined as the maximum amount of tensile stress that a metal can bear without failure. Yield Strength- it is defined as the Toughness-

Commonly used Metals

Following are the most commonly used metals in manufacturing Iron It is further classified as: Cast Iron, Steel and its alloysSteel is further classified on the basis of carbon pecentage. High Carbon Low Carbon and Medium Carbon Steel.

Material and Engg properties

The commonly used material for Sheet Metal Working in an Automobile Industry is as following along with their physical properties
As per Is 1079 Grade O, Grade D, Grade DD Grade EDD Grade St 34 Grade st 42 Grade st 52

 Blanking:- It is the operation of cutting a flat shape from sheet

metal. The article punched out is called the blank and is the required product of the operation. The hole and the material left behind are discarded as waste. It is usually the first step of series of operations.

 CUT-OFF:- Cut-off operations are those in which strip

of suitable length is cut to length. Preliminary operations before cutting off include piercing, notching, and embossing. It is as shown in figure below.

 Compounding:- It is the process of piercing and blanking simultaneously at same station. Compound dies are more expensive to build and they are used where considerable accuracy is required in the part.

 Trimming:- This operation consists of cutting

unwanted excess material from the periphery of a previously formed product.

 Piercing:- It is a cutting operation by which various

shaped holes are made in sheet metal. Punching is similar to blanking except that in punching the hole is the desired product, the material punched out to form the hole being waste

 Shaving:-The edges of a blanked part are generally

rough, uneven and unsquare. Accurate dimensions of the part are obtained by removing a thin strip of metal along the edges.

 Broaching:-The use of a cutting tool with a series of

teeth that is used to change the shape or dimensions of a hole. Broaching can also be used to remove material from a workpiece surface.

 Horning:- Horn dies are provided with an arbor or Horn over which the parts are placed for secondary operations such as seaming.

 Side Cam Operations : Piercing a no. of holes simultaneously around a shell is done in as in cam die

 Bending : Bending Dies apply simple bending to stampings. A simple bending is one which the line of bend is straight.

 Forming:- Forming dies apply more complex to work pieces. The line of Bend is curved instead of straight and the metal is subjected to plastic flow or deformation.

 Drawing:- Drawing dies transform flat sheet of metal into cups, shells, or other drawn shapes by subjecting the material to serve plastic deformation.

 Curling:- Curling does curl the edges of drawn shells to provide strength and rigidity. The curl may be applied over a wire ring for increased strength.

 Bulging:- Bulging dies expand the bottom of previously drawn shells. The bulged bottoms of some types of coffee pots are formed in bulging dies.

 Swaging:- In Swaging operations, drawn shells or tube are reduced in diameter for a portion of their lengths. The operation is so called necking.

 Extruding:- Extruding dies cause metal to be extruded or squeezed out, much as toothpaste s extruded from its tube when pressure is applied.

Sheet Metal Operations

Main Operations in Sheet Metal technology. Blanking, Cut-Off, Compounding, Trimming, Piercing, Shaving, Broaching, Horning, Side Cam operation, Bending, Forming, Drawing, Curling, Bulging, Swaging, Extruding, Cold Forming,

 Cold Forming:- In cold forming operations , metal is subjected to high pressure and caused to flow into a predetermined form. In coining, the metal is caused to flow into the shape of the die cavity. Coins such as nickels, dimes, and quarters are produced in coining dies.