The document discusses various sheet metal processes and formability testing methods. It covers common sheet metal forming operations like shearing, bending, drawing, and specialized processes such as hydroforming, rubber pad forming, spinning, and super plastic forming. It also describes properties of sheet metals, different types of presses, and factors that influence formability testing methods like the Erichsen and Olsen tests which evaluate formability based on metrics like stretchability and drawing ratio.
Introduction to casting, Major classifications of casting, Casting terminology, Characteristics of molding sand, Constituents of foundry sand, Patterns and their types, Cores and types of cores, Gating system, Types of gates, Solidification, Riser system, Types of riser, Types of allowances, Directional Solidification, Defects in casting, Riser design(Chvorinov's rules), Advanced casting techniques:Shell molding, Permanent mould casting, Vacuum die casting, Low pressure die casting, Continuous casting, Squeeze casting, Slush casting, Vacuum casting, Die Casting, Centrifugal casting, Investment casting
Sheet metal characteristics - Typical shearing operations, bending and drawing operations – Stretch forming operations –– Formability of sheet metal – Test methods – Working principle and application of special forming processes - Hydro forming – Rubber pad forming – Metal spinning – Introduction to Explosive forming, Magnetic pulse forming, Peen forming, Super plastic forming.
Hot working and cold working of metals – Forging processes – Open, impression and closed die forging – Types of Forging Machines – Typical forging operations. Rolling of metals– Types of Rolling – Flat strip rolling – shape rolling operations – Defects in rolled parts. Principle of rod and wire drawing – Tube drawing – Principles and types of Extrusion – Hot and Cold extrusion.
Introduction to casting, Major classifications of casting, Casting terminology, Characteristics of molding sand, Constituents of foundry sand, Patterns and their types, Cores and types of cores, Gating system, Types of gates, Solidification, Riser system, Types of riser, Types of allowances, Directional Solidification, Defects in casting, Riser design(Chvorinov's rules), Advanced casting techniques:Shell molding, Permanent mould casting, Vacuum die casting, Low pressure die casting, Continuous casting, Squeeze casting, Slush casting, Vacuum casting, Die Casting, Centrifugal casting, Investment casting
Sheet metal characteristics - Typical shearing operations, bending and drawing operations – Stretch forming operations –– Formability of sheet metal – Test methods – Working principle and application of special forming processes - Hydro forming – Rubber pad forming – Metal spinning – Introduction to Explosive forming, Magnetic pulse forming, Peen forming, Super plastic forming.
Hot working and cold working of metals – Forging processes – Open, impression and closed die forging – Types of Forging Machines – Typical forging operations. Rolling of metals– Types of Rolling – Flat strip rolling – shape rolling operations – Defects in rolled parts. Principle of rod and wire drawing – Tube drawing – Principles and types of Extrusion – Hot and Cold extrusion.
Introduction to casting, Major classifications of casting, Casting terminology, Characteristics of molding sand, Constituents of foundry sand, Patterns and their types, Cores and types of cores, Gating system, Types of gates, Solidification, Riser system, Types of riser, Types of allowances, Directional Solidification, Defects in casting, Riser design(Chvorinov's rules), Advanced casting techniques:Shell molding, Permanent mould casting, Vacuum die casting, Low pressure die casting, Continuous casting, Squeeze casting, Slush casting, Vacuum casting, Die Casting, Centrifugal casting, Investment casting
Introduction Hot Working and Cold Working of Metals Forging Processes- Open, impression die forging, Closed die forging-forging operation Rolling of metals-types of rolling- Flat strip rolling-shape rolling operation -Defects in rolled parts- Principle of rod and wire drawing-tube drawing -Principle of extrusion Types-hot and cold extrusion.
Introduction to casting, Major classifications of casting, Casting terminology, Characteristics of molding sand, Constituents of foundry sand, Patterns and their types, Cores and types of cores, Gating system, Types of gates, Solidification, Riser system, Types of riser, Types of allowances, Directional Solidification, Defects in casting, Riser design(Chvorinov's rules), Advanced casting techniques:Shell molding, Permanent mould casting, Vacuum die casting, Low pressure die casting, Continuous casting, Squeeze casting, Slush casting, Vacuum casting, Die Casting, Centrifugal casting, Investment casting
Introduction Hot Working and Cold Working of Metals Forging Processes- Open, impression die forging, Closed die forging-forging operation Rolling of metals-types of rolling- Flat strip rolling-shape rolling operation -Defects in rolled parts- Principle of rod and wire drawing-tube drawing -Principle of extrusion Types-hot and cold extrusion.
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1. SHEET METAL PROCESSES
Sheet metal characteristics - Typical shearing operations, bending and
drawing operations – Stretch forming operations –– Formability of sheet
metal – Test methods – Working principle and application of special
forming processes - Hydro forming – Rubber pad forming – Metal
spinning – Introduction to Explosive forming, Magnetic pulse forming,
Peen forming, Super plastic forming.
2. Introduction
The working of metal thickness from 3mm to 5mm
with hand tools and simple machines into various
forms is known as sheet metal work.
Sheet metals
Black iron
Galvanized iron
Stainless steel
Brass
Copper
Zinc , Aluminium, tin plate and lead.
15. Blanking
Blanking is the operation of cutting a flat shape from
the sheet metal
Piercing or punching:
* It is the operation of producing the hole on the work
piece by a punch
20. - Roll Forming
If the edges are formed to a desired shape in the form of bend is
made on the sheet metal
- Seaming
The process of providing lock between the two edges of the
different work metal.
SHEARING OPERATION - DRAWING
- Deep Drawing
Length of the part drawn is deeper then width.
- Box Drawing
Length of the part drawn is lesser then width
21. STRETCH FORMING OPERATION
Stretching is the process of stressing the work blank beyond its elastic limit
by moving a form block towards the blank.
FORM BLOCK METHOD
30. 3.0 METAL SPINNING
a) Manual Spinning
b) Power Spinning
Applications: Ash trays, flower pots, lamp shades, missile and radar units
31. 4).EXPLOSIVE FORMING PROCESSES
- Stand off operations
The explosive charge is located at some distance away from the blank
and energy is transmitted through some fluid medium such as water.
- Contact Operations
The explosive charge is directly located over the blank.
AEROSPACE COMPONENTS
32. Electro magnetic forming
The energy stored in a capacitor bank is discharged
rapidly through a magnetic coil.
EX: a ring shaped coil is placed over a tubular
workpiece.
Depends upon the shape of the die the tube will
deform when the magnetic force pushes the metal.
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36. In this process, a stream of balls or metals shots is
blasted against the surface of the sheet metal blank to
be made into the required shape.
The part to be made by the sheet metal placed on a
form block or it may be suspended from support.
37. 7.0 SUPER PLASTIC FORMING PROCESS
a) Loading
b) Forming
c) Forming
d) Release
38. This method involves in hot forming upto 1000 c
superplastic alloys using an inert gas pressure upto
50bar.
Advantage:
One step process
Minimizes amount of scrap
Higher material elongation possible
Application:
Forming of– automotive body panels, aircraft frames
42. BASIC SHEARING OPERATION
2.0 Forming operations
(a) Bending
(b) Drawing
(c) Sequeezing
(d) Embossing
(e) Nibbling
It is an operation of cutting any shape from sheet metal
without special tools. It is done on a nibbling machine.
43. FORMABILITY OF SHEETMETAL
Formability = f(f1, f2)
F1 = Material Variables - ductility
F2 = Process Variables – stress system, lubrication, die design etc
Law 1 – Process of fracturing
Ductility of the same material is lower if the section size is large.
Law 2 –Law of geometrical Similitude
1 Blank are geometrically similar to dimension, thickness, width etc.
2 Unit strain at corresponding locations are identical
3 Forces required directly proportional to the square of the thickness
.
4 Consumption of work proportional to the cube of its thickness.
44. FORMABILITY TEST METHOD
1 Formability tests for bulk deformation
Elastic deformation and Plastic deformation
2 Formability test for elastic plastic deformation
1) Tensile test
a) Stretch forming - local thinning
b) Drawing operation – Lower punch by thinning under bi-axial stresses.
2) Simulative tests
a)Erichsen test – Stretchability based on erichsen number
b)Olsen test
c) Swift test - based on blank to punch diameter- drawing ratio
d) Fukui test – both assessed - based on formability index
45. Erichsen test:
standard specimen of 90mm wide is rigidly clamped
against a die having 27mm diameter opening. A special
punch of 20mm diameter is moved against the sheet
metal. The movement of the punch is continued until
the fracture starts.
Olsen test:
Die opening size of 50mm diameter