This lecture provides knowledge about design philosophy and tool materials for impact tools, which are a cost factor and eminently important for successful impact extrusion. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
The document provides information on impact extrusion processes, including definitions, classifications, process steps, and material flow and deformation characteristics. Impact extrusion involves pressing a workpiece through a die opening using a punch. There are different classifications based on tool type, material flow direction, workpiece geometry, and temperature. Key process variations include solid and hollow, forward and backward extrusion. Material flow is initially non-stationary but transitions to quasi-stationary. Strain is highest near the die opening and decreases radially. Punch and die designs impact stresses and mandrel movement.
Okay, let's calculate the center of pressure step-by-step:
1) Calculate Lx, Ly for each element using the given dimensions
2) Sum Lx = 6.25 + 9.25 + 7 + 5 + 4.25 + 1 = 32.75
3) Sum Ly = 25 + 7.05 + 12.8 + 12.5 + 4.5 + 1.57 = 63.42
4) X (distance from axis YY) = Sum Lx / Sum L = 32.75 / 32.75 = 2.5
5) Y (distance from axis XX) = Sum Ly / Sum L = 63.42 / 32.75 = 1.94
Sheet metal working involves cutting, bending, and drawing operations on thin metal sheets. There are three major categories of sheet metal processes: cutting uses shearing actions to cut sheet metal, bending strains sheet metal around a straight axis, and drawing forms sheet metal into convex or concave shapes. Common sheet metal parts are used in automobiles, appliances, furniture and other industrial and consumer products.
Design of Stage Progressive Die for a Sheet Metal Component STAY CURIOUS
Progressive die stamping is a metal forming process widely used to produce parts for various industries, such as automotive, electronics and appliances. Progressive die stamping consists of several individual work stations, each of which performs one or more different operations on the part.
Cutting tools must possess certain key characteristics like hardness, toughness, wear resistance, and chemical stability. The selection of a cutting tool material depends on factors like the work material, cutting conditions, required surface finish, and cost. Common tool materials include high-speed steel, cast cobalt alloys, cemented carbides, ceramics, cubic boron nitride, and diamond. New developments in coated tools and ceramics have improved tool performance and allowed for higher cutting speeds.
Unit -1-Theory of Metal Cutting
Manufacturing Technology is much more essential subjects for Mechanical Engineering According that i am prepare study material for Manufacturing Technology-2 UNIT wise ......1 st unit covered more then enough for this materials get wide knowledge from Manufacturing Division.....
All The Best My Dear Hearts
Remaining Units i will update soon ....
Thank you ....
By: Prof.S.Sathishkumar
The document provides information on impact extrusion processes, including definitions, classifications, process steps, and material flow and deformation characteristics. Impact extrusion involves pressing a workpiece through a die opening using a punch. There are different classifications based on tool type, material flow direction, workpiece geometry, and temperature. Key process variations include solid and hollow, forward and backward extrusion. Material flow is initially non-stationary but transitions to quasi-stationary. Strain is highest near the die opening and decreases radially. Punch and die designs impact stresses and mandrel movement.
Okay, let's calculate the center of pressure step-by-step:
1) Calculate Lx, Ly for each element using the given dimensions
2) Sum Lx = 6.25 + 9.25 + 7 + 5 + 4.25 + 1 = 32.75
3) Sum Ly = 25 + 7.05 + 12.8 + 12.5 + 4.5 + 1.57 = 63.42
4) X (distance from axis YY) = Sum Lx / Sum L = 32.75 / 32.75 = 2.5
5) Y (distance from axis XX) = Sum Ly / Sum L = 63.42 / 32.75 = 1.94
Sheet metal working involves cutting, bending, and drawing operations on thin metal sheets. There are three major categories of sheet metal processes: cutting uses shearing actions to cut sheet metal, bending strains sheet metal around a straight axis, and drawing forms sheet metal into convex or concave shapes. Common sheet metal parts are used in automobiles, appliances, furniture and other industrial and consumer products.
Design of Stage Progressive Die for a Sheet Metal Component STAY CURIOUS
Progressive die stamping is a metal forming process widely used to produce parts for various industries, such as automotive, electronics and appliances. Progressive die stamping consists of several individual work stations, each of which performs one or more different operations on the part.
Cutting tools must possess certain key characteristics like hardness, toughness, wear resistance, and chemical stability. The selection of a cutting tool material depends on factors like the work material, cutting conditions, required surface finish, and cost. Common tool materials include high-speed steel, cast cobalt alloys, cemented carbides, ceramics, cubic boron nitride, and diamond. New developments in coated tools and ceramics have improved tool performance and allowed for higher cutting speeds.
Unit -1-Theory of Metal Cutting
Manufacturing Technology is much more essential subjects for Mechanical Engineering According that i am prepare study material for Manufacturing Technology-2 UNIT wise ......1 st unit covered more then enough for this materials get wide knowledge from Manufacturing Division.....
All The Best My Dear Hearts
Remaining Units i will update soon ....
Thank you ....
By: Prof.S.Sathishkumar
Sheet metal is generally sheets less than 6 mm thick that are produced through rolling. Sheet metal is widely used for industrial and non-industrial applications like aircraft wings, automotive body panels, and construction roofing. Some common sheet metal materials include aluminum-zinc alloy, galvanized steel, and cold rolled steel. Sheet metal parts offer advantages like good strength, dimensional accuracy, surface finish, and low cost. Common sheet metal manufacturing processes include cutting operations like punching, blanking, and piercing as well as bending, drawing, and squeezing.
This document discusses sheet metal working processes. It begins by explaining that sheet metal forming dates back thousands of years and is used to make a wide variety of consumer and industrial products. The main sheet metal forming processes are stretching, bending, deep drawing, and press working. Press working shapes sheet metal using dies and punches without removing material. The document then goes into details about various sheet metal forming operations, tools, and calculations for processes like bending, deep drawing, blanking, and punching.
Turret punching is a CNC process that uses a turret punch machine to punch holes in sheet metal or plastic materials according to a programmed design. The material is clamped into the machine table which then moves it to the correct X/Y location for the turret-selected punch to create the desired hole shape. Turret punching is a cold working process that produces shapes in sheet metal through selective material removal. It is a fast and accurate process for making multiple holes in metal sheets.
The document discusses the process of extrusion. It begins with an introduction to extrusion, defining it as reducing the cross-section of metal by forcing it to flow through a die under high pressure. It then covers the basic extrusion process using diagrams. The document goes on to classify extrusion processes and describe various types like direct/indirect, hot/cold, lateral, and hydrostatic extrusion. It also covers die design, defects, variables that affect extrusion, and applications of extrusion.
Products made through sheet metal processing include automobile bodies, cabinet appliances, electronic components, electrical parts, aerospace parts, refrigeration, and air conditioning parts, etc.
The document discusses cutting tools and their properties. It describes different types of cutting tool materials like high-speed steel, cemented carbides, ceramics, and diamond. It explains cutting tool nomenclature and defines terms like rake angle, clearance angle, nose, and flank. It also discusses factors that affect tool life like cutting conditions, work material properties, and tool material.
This chapter discusses various metal extrusion processes. It begins by defining extrusion as forcing a metal billet through a die to reduce its cross-section. Various types of extrusion processes are classified, including direct/indirect extrusion and hot/cold extrusion. Equipment for extrusion like presses and dies are also described. Examples of products made by extrusion and specific processes like tube extrusion are provided. The chapter aims to provide useful background on extrusion processes and their analysis.
This document provides an overview of sheet metal forming processes. It discusses various sheet metal operations including cutting (shearing) operations like punching, blanking, and trimming as well as forming operations like bending, drawing, and squeezing. Bending operations including V-bending and edge bending are described. Drawing operations for forming hollow shapes are also covered along with squeezing processes like embossing and coining.
Sheet metal characteristics – shearing, bending and drawing operations – Stretch forming operations – Formability of sheet metal – Test methods –special forming processes-Working principle and applications – Hydro forming – Rubber pad forming – Metal spinning– Introduction of Explosive forming, magnetic pulse forming, peen forming, Super plastic forming – Micro forming.
Press tools are commonly used in hydraulic, pneumatic, and mechanical presses to produce the sheet metal components in large volumes. Generally press tools are categorized by the types of operation performed using the tool, such as blanking, piercing, bending, forming, forging, trimming etc.Press tools are commonly used in hydraulic, pneumatic, and mechanical presses to produce the sheet metal components in large volumes. Generally press tools are categorized by the types of operation performed using the tool, such as blanking, piercing, bending, forming, forging, trimming etc.
The document introduces metal forming processes. It defines metal forming as shaping metallic materials through plastic deformation, where the shape changes permanently in contrast to elastic deformation. It describes bulk deformation processes as involving large plastic deformation without changing volume. These include hot working like forging above the recrystallization temperature for easier forming, and cold working like rolling at room temperature for better accuracy. Sheet forming processes change the shape but not the cross-section, operating on thin metal sheets using stamping presses.
This document provides an overview of metal forging processes. It begins with an introduction to forging and then classifies forging processes into hammer/drop forging and press forging. It further classifies processes as open-die forging or closed-die forging. The document also discusses typical forging operations, the types of forging machines, and provides examples of specific forging processes. It describes the goals of minimizing forging defects and achieving the desired final shape and properties of forged parts.
Sheet metal operations involve cutting, forming, and finishing processes to manufacture components from thin metal plates less than 5mm thick. Cutting processes like shearing, punching, and blanking apply forces to separate material, while forming processes like drawing, spinning, bending, and embossing shape the metal without cracking. Common sheet metals include steel, aluminum, and titanium used in automotive and aircraft bodies, appliances, and more. Key forming operations are stretching, spinning, bending, and embossing which deform the metal over dies into desired contours.
Shearing of metals is a sheet metalworking process used to cut relatively thin sheets of metal less than 6mm thick. Sheet metal parts are commonly used in automobiles, appliances, furniture and other consumer and industrial products. Common sheet metal processes include cutting, bending, drawing, punching, blanking, perforating and others. Sheet metal operations require precision tools and dies to cut cleanly and maintain dimensional accuracy and surface finish of the cut parts. Process parameters like shear angle, clearance and forces must be properly controlled to achieve quality edges and avoid defects.
The document discusses thread rolling, including:
- Thread rolling strengthens material without cutting, lowering costs and speeds production.
- Proper material selection, tooling, speeds and feeds, and gaging are required for quality threads.
- Common issues like slivers, incorrect pitch, and mismatched helix angles can be avoided through optimization of rolling conditions, tool synchronization, and material selection.
This document discusses the design of an angle plate jig by a group of students. The jig is intended to drill 8mm holes on a given workpiece. Key points:
- The group is divided into two sections to collaborate on the design project.
- The design of the jig will consider factors like the material selection for each part and geometric analysis to optimize output and ensure interchangeability.
- The design process will start conceptually and result in a 3D model created in Solidworks.
- The objectives are to produce a jig that increases productivity and reduces costs while maintaining accuracy and consistency.
Manufacturing Engineering 2, cutting tools and tool holdersGaurav Mistry
Detail study of cutting tool materials, some special materials, carbide tip tools, carbide inserts, types, carbide insert holders, ISO designation of carbide inserts, single point cutting tool nomenclature and angles, tool geometry, Tool life, tool wear and types, machinability
TALAT Lecture 2102.02: An Upper Casing for an Automobile Steering Column, Spe...CORE-Materials
This lecture offers an example of product development. It imparts knowledge about cold forging of aluminium and choice of alloy. It provides insight into how to develop a product using the general specifications and the interaction between form, material and processing chain and the importance of being thoroughly familiar with the different design materials, their processing possibilities and properties. The lecture is recommended for those situations, where a brief, general background information about aluminium is needed as an introduction of other subject areas of aluminium application technologies. This lecture is part of the self-contained course "Aluminium in Product Development", which is treated under TALAT lectures 2101 and 2102.
This lecture describes the factors important for the quality assurance of adhesive joining; it gives information about the destructive and non-destructive testing methods for the quality control of adhesive joining. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
Sheet metal is generally sheets less than 6 mm thick that are produced through rolling. Sheet metal is widely used for industrial and non-industrial applications like aircraft wings, automotive body panels, and construction roofing. Some common sheet metal materials include aluminum-zinc alloy, galvanized steel, and cold rolled steel. Sheet metal parts offer advantages like good strength, dimensional accuracy, surface finish, and low cost. Common sheet metal manufacturing processes include cutting operations like punching, blanking, and piercing as well as bending, drawing, and squeezing.
This document discusses sheet metal working processes. It begins by explaining that sheet metal forming dates back thousands of years and is used to make a wide variety of consumer and industrial products. The main sheet metal forming processes are stretching, bending, deep drawing, and press working. Press working shapes sheet metal using dies and punches without removing material. The document then goes into details about various sheet metal forming operations, tools, and calculations for processes like bending, deep drawing, blanking, and punching.
Turret punching is a CNC process that uses a turret punch machine to punch holes in sheet metal or plastic materials according to a programmed design. The material is clamped into the machine table which then moves it to the correct X/Y location for the turret-selected punch to create the desired hole shape. Turret punching is a cold working process that produces shapes in sheet metal through selective material removal. It is a fast and accurate process for making multiple holes in metal sheets.
The document discusses the process of extrusion. It begins with an introduction to extrusion, defining it as reducing the cross-section of metal by forcing it to flow through a die under high pressure. It then covers the basic extrusion process using diagrams. The document goes on to classify extrusion processes and describe various types like direct/indirect, hot/cold, lateral, and hydrostatic extrusion. It also covers die design, defects, variables that affect extrusion, and applications of extrusion.
Products made through sheet metal processing include automobile bodies, cabinet appliances, electronic components, electrical parts, aerospace parts, refrigeration, and air conditioning parts, etc.
The document discusses cutting tools and their properties. It describes different types of cutting tool materials like high-speed steel, cemented carbides, ceramics, and diamond. It explains cutting tool nomenclature and defines terms like rake angle, clearance angle, nose, and flank. It also discusses factors that affect tool life like cutting conditions, work material properties, and tool material.
This chapter discusses various metal extrusion processes. It begins by defining extrusion as forcing a metal billet through a die to reduce its cross-section. Various types of extrusion processes are classified, including direct/indirect extrusion and hot/cold extrusion. Equipment for extrusion like presses and dies are also described. Examples of products made by extrusion and specific processes like tube extrusion are provided. The chapter aims to provide useful background on extrusion processes and their analysis.
This document provides an overview of sheet metal forming processes. It discusses various sheet metal operations including cutting (shearing) operations like punching, blanking, and trimming as well as forming operations like bending, drawing, and squeezing. Bending operations including V-bending and edge bending are described. Drawing operations for forming hollow shapes are also covered along with squeezing processes like embossing and coining.
Sheet metal characteristics – shearing, bending and drawing operations – Stretch forming operations – Formability of sheet metal – Test methods –special forming processes-Working principle and applications – Hydro forming – Rubber pad forming – Metal spinning– Introduction of Explosive forming, magnetic pulse forming, peen forming, Super plastic forming – Micro forming.
Press tools are commonly used in hydraulic, pneumatic, and mechanical presses to produce the sheet metal components in large volumes. Generally press tools are categorized by the types of operation performed using the tool, such as blanking, piercing, bending, forming, forging, trimming etc.Press tools are commonly used in hydraulic, pneumatic, and mechanical presses to produce the sheet metal components in large volumes. Generally press tools are categorized by the types of operation performed using the tool, such as blanking, piercing, bending, forming, forging, trimming etc.
The document introduces metal forming processes. It defines metal forming as shaping metallic materials through plastic deformation, where the shape changes permanently in contrast to elastic deformation. It describes bulk deformation processes as involving large plastic deformation without changing volume. These include hot working like forging above the recrystallization temperature for easier forming, and cold working like rolling at room temperature for better accuracy. Sheet forming processes change the shape but not the cross-section, operating on thin metal sheets using stamping presses.
This document provides an overview of metal forging processes. It begins with an introduction to forging and then classifies forging processes into hammer/drop forging and press forging. It further classifies processes as open-die forging or closed-die forging. The document also discusses typical forging operations, the types of forging machines, and provides examples of specific forging processes. It describes the goals of minimizing forging defects and achieving the desired final shape and properties of forged parts.
Sheet metal operations involve cutting, forming, and finishing processes to manufacture components from thin metal plates less than 5mm thick. Cutting processes like shearing, punching, and blanking apply forces to separate material, while forming processes like drawing, spinning, bending, and embossing shape the metal without cracking. Common sheet metals include steel, aluminum, and titanium used in automotive and aircraft bodies, appliances, and more. Key forming operations are stretching, spinning, bending, and embossing which deform the metal over dies into desired contours.
Shearing of metals is a sheet metalworking process used to cut relatively thin sheets of metal less than 6mm thick. Sheet metal parts are commonly used in automobiles, appliances, furniture and other consumer and industrial products. Common sheet metal processes include cutting, bending, drawing, punching, blanking, perforating and others. Sheet metal operations require precision tools and dies to cut cleanly and maintain dimensional accuracy and surface finish of the cut parts. Process parameters like shear angle, clearance and forces must be properly controlled to achieve quality edges and avoid defects.
The document discusses thread rolling, including:
- Thread rolling strengthens material without cutting, lowering costs and speeds production.
- Proper material selection, tooling, speeds and feeds, and gaging are required for quality threads.
- Common issues like slivers, incorrect pitch, and mismatched helix angles can be avoided through optimization of rolling conditions, tool synchronization, and material selection.
This document discusses the design of an angle plate jig by a group of students. The jig is intended to drill 8mm holes on a given workpiece. Key points:
- The group is divided into two sections to collaborate on the design project.
- The design of the jig will consider factors like the material selection for each part and geometric analysis to optimize output and ensure interchangeability.
- The design process will start conceptually and result in a 3D model created in Solidworks.
- The objectives are to produce a jig that increases productivity and reduces costs while maintaining accuracy and consistency.
Manufacturing Engineering 2, cutting tools and tool holdersGaurav Mistry
Detail study of cutting tool materials, some special materials, carbide tip tools, carbide inserts, types, carbide insert holders, ISO designation of carbide inserts, single point cutting tool nomenclature and angles, tool geometry, Tool life, tool wear and types, machinability
TALAT Lecture 2102.02: An Upper Casing for an Automobile Steering Column, Spe...CORE-Materials
This lecture offers an example of product development. It imparts knowledge about cold forging of aluminium and choice of alloy. It provides insight into how to develop a product using the general specifications and the interaction between form, material and processing chain and the importance of being thoroughly familiar with the different design materials, their processing possibilities and properties. The lecture is recommended for those situations, where a brief, general background information about aluminium is needed as an introduction of other subject areas of aluminium application technologies. This lecture is part of the self-contained course "Aluminium in Product Development", which is treated under TALAT lectures 2101 and 2102.
This lecture describes the factors important for the quality assurance of adhesive joining; it gives information about the destructive and non-destructive testing methods for the quality control of adhesive joining. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
TALAT Lecture 3801: Manufacturing Examples and FundamentalsCORE-Materials
This lecture describes the fundamentals of the superplastic behaviour phenomenon of aluminium alloys and the basic process parameters which govern the manufacturing of superplastic sheet metal parts. General background in production engineering and material science is assumed.
TALAT Lecture 3503: Finishing and other Supplementary OperationsCORE-Materials
This lecture describes supplementary fabrication measures for impact extruded parts and gives some examples of finished impacts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
TALAT Lecture 2301: Design of Members Example 4.4: Bending moment resistance ...CORE-Materials
This 3 sentence summary provides the key details about the document:
1) The document is a 10 page example from a lecture on designing members for bending moment that analyzes the bending moment resistance of a welded hollow section with outstands using a class 4 cross section.
2) It presents the geometry, material properties, nodes, and elements of the hollow cross section and performs iterative calculations of the effective cross section area, stress distribution, and effective thicknesses accounting for any heat affected zones to determine the bending moment resistance.
3) The example is considered comprehensive because it shows calculations in detail, covers all classes of cross sections, and demonstrates how to increase effective thickness for non-fully stressed elements through
TALAT Lecture 4205: Testing Methods for Welded JointsCORE-Materials
This lecture gives information about the relevant non-destructive and destructive testing methods for aluminium welded joints. Background in production welding and quality assurance is assumed.
This lecture describes fabrication processes for superplastic forming, i.e. female and male die forming, and the criteria for selecting the correct process. General background in production engineering and material science is assumed.
This lecture helps to understand how the properties of forgings evolve during the manufacturing process. General understanding of metallurgy and deformation processes is assumed.
This lecture provides a background on aluminium alloys suitable for impact extrusion. It draws attention to raw material parameters which may affect the properties of impact extruded parts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
This document provides an overview of application characteristics for rivet and clinch joints. It discusses design considerations such as choosing rivet diameters and distances from edges. It also covers material and tooling parameters that influence joint quality like surface finish. Testing methods are described for shear-tensile, fatigue, and impact tests. Sample geometries and results are shown. Finally, it briefly discusses cost considerations for different joining technologies.
TALAT Lecture 2301: Design of Members Example 5.5: Axial force resistance of ...CORE-Materials
This 3-page document provides an example calculation for determining the axial force resistance of a laced column. It includes dimensions, material properties, and calculations of various parameters needed for the analysis. Key steps and results are shown, such as determining the effective length, flexural buckling resistance, and checking that the lacing can resist the required shear force. In the end, it is determined that the lacing can adequately resist the applied axial load of 270 kN.
TALAT Lecture 5104: Basic Approaches to Prevent Corrosion of AluminiumCORE-Materials
This lecture describes important measures for the prevention of corrosion of unprotected, bare
aluminium. Basic knowledge of corrosion behaviour of aluminium and some knowledge of the electrochemical nature of corrosion is assumed
This lecture describes the detailed processes of single-step and multiple-step clinching; it shows the differences of the various clinching methods concerning the amount of shearing; it illustrates the major differences in mechanical properties of clinch joints compared with resistance spot welds. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lecture 4101 is assumed.
TALAT Lecture 4107: General Summary and Future TrendsCORE-Materials
This lecture points out the need of data sources for designing mechanical joints; it describes concepts for FEM-Modelling of mechanical joints. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lectures 4101- 4106 is assumed.
TALAT Lecture 4703: Design and Calculation of Adhesive JointsCORE-Materials
This lecture describes the basic types of loadings of adhesive joints and to give examples of recommended joint designs; it shows how to calculate the strength of adhesive joints. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
TALAT Lecture 4702: Factors Influencing the Strength of Adhesive JointsCORE-Materials
This lecture describes the factors governing the strength of adhesive joints in order to appreciate these factors for the design of adhesively bonded joints, i.e. geometry of joint, stiffness and strength of the adjoining parts, stress distribution in the adhesive layer as well as the effects of humidity and ageing. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
This lecture describes the fundamentals of bending and folding aluminium sheet; it also describes different methods in design of folding tools. Background in production engineering and sheet metal forming and familiarity with the subject matter covered in TALAT This lectures 3701- 3705 is assumed.
TALAT Lecture 4101: Definition and Classification of Mechanical Fastening Met...CORE-Materials
This document provides an overview of mechanical fastening methods for joining aluminum parts, including definitions and classifications. It discusses screw joints, folds, rivets, and clinching. Screw joints can be pierced, through, or blind holes. Folds are formed locking joints created through folding, interlocking, and pressing sheets together. Riveting includes indirect and direct methods. Blind rivets have a predetermined break point. The document aims to introduce the principal types of mechanical fastening methods for aluminum.
TALAT Lecture 4300: Beam Welding Processes of AluminiumCORE-Materials
The document provides information on beam welding processes for aluminium, including:
- Electron beam welding principles and process steps for deep welding. It describes terms used and discusses weldability of aluminium alloys.
- Laser welding principles and comparisons to electron beam welding. Solid-state lasers commonly used for thinner sheets while gas lasers used for thicker sheets.
- Laser cutting principles and comparisons of laser beam cutting to plasma cutting. Laser cutting well suited for aluminium.
- References 14 figures and discusses objectives of introducing beam welding and cutting techniques for aluminium. Provides overview of key beam welding and cutting topics.
3341906 pms lab_manual_prepared by vipul hinguVipul Hingu
The document discusses measuring wear on machine parts. It describes measuring wear on cylindrical shafts, pistons, guide ways, and threads. For shafts, wear is measured on journals, keyways, splines, and threads. Guide way wear is measured using a universal bridge and dial gauge. Thread wear is measured by assembling a nut and bolt. The document provides details on repair and restoration methods for worn machine parts.
TALAT Lecture 3504: Impact Extrusion Design Aspects and PropertiesCORE-Materials
This lecture describes the forms and shapes which can be fabricated by impact extrusion; it points out limiting factors in the freedom of design of impacts; it helps to learn about the factors affecting tolerances and surface roughness of impacts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
The document discusses various types of welds used in structural engineering including fillet welds, groove welds, slot welds, and plug welds. Fillet welds are the most commonly used, comprising approximately 80% of welds in structural applications. The document outlines the properties and design considerations for fillet welds, including weld size, throat thickness, end returns, overlap, and stresses in fillet welds. Weld symbols and their notation are also presented.
This document provides an overview of shearing and bending processes, including:
1) Shearing involves cutting sheet metal using a punch and die, while bending deforms metal around a straight axis using tools like a finger brake.
2) The lab objectives are to familiarize students with shearing and bending and analyze springback in aluminum bending.
3) Finite element analysis simulations demonstrate the deformation and springback during bending.
1. The document discusses sheet metal forming processes including shearing, bending, and springback. It provides definitions and formulas for calculating forces in shearing and springback in bending.
2. An lab experiment is described that involves bending aluminum strips using a finger brake machine and measuring the resulting bend radii and angles to analyze springback.
3. Finite element analysis simulations are shown illustrating the deformation during bending and springback.
Cutting Operations
Bending Operations
Drawing
Other Sheet Metal Forming Operations
Dies and Presses for Sheet Metal Processes
Sheet Metal Operations Not Performed on Presses
Bending of Tube Stock
This document discusses two types of screws used to assemble plastic parts: thread forming screws and thread cutting screws. Thread forming screws deform the plastic material to form internal threads, while thread cutting screws remove plastic material to form threads. The document focuses on thread forming screws and describes several types designed specifically for plastics, including HiLo, DST, Plastite, and PT screws. It explains how the thread design and angle of PT screws provides advantages over traditional metal screws like reducing radial stresses and increasing pullout loads when used in plastic assembly.
The document discusses various sheet metalworking processes including cutting, bending, drawing and other forming operations. It describes how sheet metal parts are used in a variety of industries and products. The key sheet metalworking processes like shearing, blanking, punching, bending and drawing are explained in detail through diagrams and definitions of related terminology. Various factors that influence these processes such as clearance, springback, and formability tests are also covered.
This document provides information about a sheet metal forming lab on shearing and bending. The lab objectives are to familiarize students with shearing and bending processes and analyze bending experiments to determine springback in aluminum strips. The document outlines the bending experiment procedure which involves cutting aluminum samples, bending them using different die radii, and measuring the resulting bend radii and angles to calculate springback. It also includes simulations of the bending and springback processes using finite element analysis.
The document is a presentation on cotter joints used to connect rigidly two co-axial rods subjected to axial forces. It defines a cotter joint, noting that the cotter is a tapered wedge that provides a tight fit. It lists common applications like pistons and flywheels. The taper ensures tightness during operation and easy removal for dismantling. Finally, it outlines the design considerations for the spigot, socket, collar and cotter to prevent tensile, shear and crushing failures under the load P.
The document discusses jigs and fixtures, which are tools used to precisely locate and secure workpieces during manufacturing operations like machining. It defines jigs and fixtures, describes their key elements and principles of location and clamping. It also covers different types of locating and clamping devices as well as common types of jigs like drilling jigs. Jigs are used to guide cutting tools, while fixtures only position and hold the workpiece. Together, jigs and fixtures help improve accuracy, interchangeability and efficiency of mass production.
Multi-StageSheet Metal Fromed Bolted Fastener DesignMark Brooks
This document discusses the development of a multi-stage sheet metal fastening design that eliminates nuts to reduce costs and improve manufacturing efficiency. Testing showed that while extruded, rivet, and PEM nuts exceeded torque specifications, shear/tap fasteners only marginally met specifications, failing through thread tear. To breakthrough this technology barrier, the basics of thread forming were revisited. Roll-forming threads through compression may improve performance over cutting threads.
The document discusses various sheet metal processes including shearing, punching, blanking, bending, drawing, spinning, and forming. It provides details on each process such as the basic setup, how it works, applications, advantages, and equations to calculate forces required. Key points covered include how shearing produces rough cut edges, the importance of proper clearance in punching, the stages of deep drawing including thinning, and how spinning can form axisymmetric shapes through localized deformation.
study of jig machine, its types & operation Umair Raza
1) A jig is a device that holds and guides a workpiece or tool to ensure interchangeability and accuracy in manufacturing.
2) Key factors to consider in jig design include the component, locating elements, machine capacity, clamping, tool guidance, and fool-proofing.
3) Common types of jigs include template jigs, channel jigs, angle plate jigs, turn-over jigs, leaf or latch jigs, box jigs, and multi-station jigs.
Sheet metal forming processes Erdi Karaçal Mechanical Engineer University of ...Erdi Karaçal
The document describes various sheet metal forming processes and provides characteristics of each. It discusses roll forming for parts with complex cross-sections and high production rates but high tooling costs. Stretch forming is described as suitable for low quantity production but with high labor costs and tooling/equipment costs depending on part size. Drawing is outlined as having high production rates but also high tooling and equipment costs.
The document discusses the design of various types of screw fasteners. It describes screw threads as helical grooves cut into cylindrical surfaces. Screw joints are commonly used for assembly and have advantages of being convenient to assemble/disassemble, reliable, and inexpensive due to standardization. The main types of screw fasteners are bolts, screws, studs, tapping screws, and set screws. Stresses in screw joints include tension, torsional shear, shear across threads, crushing stress, and bending stress. Screw joints are also subjected to stresses from initial tightening and external loads. Design considerations are discussed for bolted joints under eccentric loading parallel or perpendicular to the bolt axis.
The document discusses sheet metalworking processes. It defines sheet metalworking as cutting and forming operations on thin metal sheets between 0.4-6mm thick. Common operations include cutting (shearing, blanking, punching), bending, drawing and other specialized processes. Key factors in determining the feasibility and setup of operations like clearance, bend allowance, and tests for drawing are also covered. Dies, presses and press components used to perform sheet metalworking are described.
This document provides information on bending theory and design principles for bending operations. It discusses the following key points in 3 sentences:
Types of bending covered include V-bending, edge bending, and flanging. Springback occurs as the bent part partially recovers its original shape after bending forces are removed. The document outlines methods to compensate for springback like overbending and bottoming, and provides formulas to estimate springback and calculate bending allowance and force.
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1. TALAT Lecture 3505
Tools for Impact Extrusion
10 pages, 10 figures
Basic Level
prepared by Klaus Siegert and Manfred Kammerer, Institut für Umformtechnik,
Universität Stuttgart
Objectives:
− To provide knowledge about design philosophy and tool materials for impact tools,
which are a cost factor and eminently important for successful impact extrusion
Prerequisites:
− Basic knowledge about the formability of metals
− Background in mechanical engineering
Date of Issue: 1994
EAA - European Aluminium Association
2. 3505 Tools for Impact Extrusion
Table of Contents:
3505 Tools for Impact Extrusion .......................................................................2
3505.01 Construction of Impact Tools .................................................................. 2
3505.02 Design of Punches ..................................................................................... 4
3505.03 Design of Press Sleeves ............................................................................. 4
3505.04 Example of an Impact Tool...................................................................... 7
3505.05 Materials for Impact Tools ...................................................................... 9
3505.06 List of Figures............................................................................................ 10
3505.01 Construction of Impact Tools
Considering the high cost of process and tool development, impact extrusion should best
be used for medium to large production series. This means that the impact extrusion
tools should be designed for a high life. In practice, one usually uses tool systems which
consist of standardised base frames and interchangeable inserts specific for the work-
piece. These inserts are mostly punches, sleeves (usually as a reinforced formation) and
counter punches or ejectors. Tools used for impact extrusion of aluminium are subjected
mainly to wear. Tool breakage during the impact extrusion of aluminium occurs rather
seldom. Production of impacts made of high-strength and deformation resistant
aluminium alloys is only successful with high-strength tools with complicated
geometrical forms.
The basic construction of tools is similar for all impact extrusion processes. Figure
3505.01.01 shows the construction of a tool for „solid forward“ impact extrusion.
Guiding column frames, available as standardised elements, can be utilised as a useful
help for assembling and aligning, but is not suited for absorbing lateral forces which
occur during pressing. Normally, horizontal toggle-lever presses are used for the single
step impact extrusion of aluminium.
TALAT 3505 2
3. Construction of Impact Extrusion Tools
Tool for Solid Forward Impact Extrusion
Backing plate
Punch
Press sleeve
Reinforcement ring
Backing plate
Knockout (ejector)
Source: R.Geiger / R.Woska
alu
Training in Aluminium Application Technologies
Construction of Impact Extrusion Tools 3505.01.01
The assembly room of a horizontal toggle-lever press is illustrated in Figure
3505.01.02. The alignment of die and punch is made possible by using wedges on the
die side.
Tool assembly and construction
Tool assembly room of a horizontal toggle-lever press
Assembly room: front end-position of punches
Punch adjustment
Die holder Punch holder
Adjustment using 4 wedges in the
plane at right angles to the middle axis
Source: Co. Schüler / Alutec Tightening bolts
alu
Training in Aluminium Application Technologies
Horizontal Toggle-Lever Press 3505.01.02
TALAT 3505 3
4. 3505.02 Design of Punches
The punch is a component subjected to high stresses. The loading it is subjected to is of
the compressive and buckling type. The buckling load is minimised by using as short
punches as possible. For this purpose, a punch head is screwed on to the punch shaft
with a reamed bolt. Figure 3505.02.01 illustrates the most commonly used punch head
forms for the „cup backward“ impact extrusion of cans, tubes and shells.
Design of Punches
Grooves
Air Punch
flutes Valve
a) b) c) d) e)
a) Punch for cup backward impact extrusion d) Punch with mandrel for fabricating shells with
of parts with closed and level base differently formed hollow pins in the base
b) Punch with recess at the punch end for e) Punch with ventilation flutes for extremely
impacts with an internal ring thin-walled shells
c) Punch with grooves or notches for fabricating
profiled bases
alu
Training in Aluminium Application Technologies
Design of Punches 3505.02.01
3505.03 Design of Press Sleeves
The design and calculation of a press sleeve depends on the form of the work-piece and
on the stresses occurring during the forming.
The press sleeves used for solid and for hollow impact extrusion are usually single-piece
types or types which are split longitudinally or transversally. Single-piece types are
usual for low press forces as in the case of pressing aluminium. For longitudinally split
sleeves, a die insert with an oversize of 2 to 4 parts per thousand in diameter is used. For
cup impact extrusion of aluminium, single-piece and two-piece transversally split dies
with ejectors are normally used. For the cup impact extrusion of aluminium tubes,
single-piece dies without ejectors are usual. For transversal splitting, an axial pre-strain
is recommended, in order to prevent an opening-up of the transverse joint under the
TALAT 3505 4
5. axial forces and thus allowing material to flow into the gap during forming (Figure
3505.03.01)
Design of Press Sleeves
for Solid and Hollow Impact Extrusion
a a a
c c c
b b b
d d d
g e g g e
i f i f i f
k k h k
h h
l a
Single-Piece Longitudinally Transversally
Split Split
a - shrunk-on-ring e - shoulder inlet radius i - exit diameter
b - pressing sleeve f - shoulder k - clearance grinding
c - inside diameter of g - shoulder exit radius l - die insert
pressing sleeve h - extrusion lip
d - die opening angle
Source: K. Lange
alu
Training in Aluminium Application Technologies
Design of Press Sleeves 3505.03.01
Figure 3505.03.02 shows several variations in construction of reinforced press die
combinations. Reinforced and radially prestrained dies are essential for pressing high-
strength aluminium alloys. Press sleeves are prestrained radially by slipping
reinforcement rings over them. The number of rings used depends on the magnitude of
the internal pressure acting on the die, on the tool material as well as on the available
assembly space.
TALAT 3505 5
6. Variations in Construction of Press
Die Combinations
da d1 da d1 d2 d d2 d
1 1
di di di di
da da
Simple reinforcement Simple reinforcement Double reinforcement Double reinforcement
cylindrical joint conical joint cylindrical joint conical joint
Internal Stress pi Number of Diameter Ratio Approximation Equation for
N / mm² Reinforcement Rings da / di joint Diameter df
mm
up to 1.000 0 2 to 4 -
1.00 to 1.600 1 2.5 to 4 d1 >> 0.9 x (da x di)1/2
1.600 to 2.000 2 d1 : di = 1.6 to 1.8
3 to 4.5 d2 : di = 2.2 to 2.8
Source: K.Lange
alu Variations in Construction of Press
Training in Aluminium Application Technologies Die Combinations 3505.03.02
Combined dies (die bindings) can be calculated using the VDI guideline 3186 or
roughly constructed using the guide values given in the table in Figure 3505.03.02.
Since the internal pressures created during the impact extrusion of aluminium and its
alloys seldom exceed 1,500 N/mm², simple reinforcements are sufficient to equalise the
tangential tensile stress in the inside wall.
Figure 3505.03.03 illustrates the theoretical stress distribution that occurs in the
individual parts of a reinforced combination with and without a superimposed internal
stress. It can be seen here that the tangential tensile stress is clearly reduced. If a proper
type of reinforcement is used, overloading cracks in the press sleeves can be reliably
avoided.
TALAT 3505 6
7. Theoretical Distribution of Stress
in Press Die Combination
+σ
pi pi
σr σt σr σt
−σ
without superimposed internal stress pi - internal stress
with superimposed internal stress σr - radial stress
σt - tangential stress
Source: R.Geiger / R.Woska
alu Theoretical Distribution of Stress in
Training in Aluminium Application Technologies Press Die Combination 3505.03.03
3505.04 Example of an Impact Tool
Aluminium cups with various ratios of lengths to breadths are impact extruded.
Rectangular cups having a length to breadth ratio of less than 1.5 can, as a rule, be easily
produced. In the printed circuit board holder, shown in Figure 3505.04.01, for the
electronic industry, the ratio between length and breadth is unfavourable, so that the
material flow during impact extrusion causes the holder to crack along the middle of the
longer side. Besides this, warping can occur at the opening and along the longer side.
TALAT 3505 7
8. Example of an Impact Extrusion Tool
Integrated Circuit Board Holder
Z
35 Material: Al 99.5
150
Detail Z
70
1.2
Source: M.Kammerer
alu
Training in Aluminium Application Technologies
Impact Extruded Board Holder 3505.04.01
By a proper choice of lubricants and by optimising the punch form, it is possible to
influence the material flow in such a manner that the impact produced is true to form
and within the required tolerance. The punch form can be optimised as described below.
In order to have a favourable material flow, the short sides of the punch are bevelled, as
shown in Figure 3505.04.02. Grooves cut into the end face of the punch make the
material flow slower and at the same time help to give the punch lateral stability during
the pressing operation.
Example of a Tool
Punch for an Integrated Circuit Board Holder Impact
Bevelling to control
material flow
Functional grooves
Stabilizer Groove
Source: M.Kammerer
alu Example of a Tool
Training in Aluminium Application Technologies Punch for a Board Holder Impact 3505.04.02
TALAT 3505 8
9. Figure 3505.04.03 shows a sketch of a die combination with a base insert which was
used to produce the board holder impact.
Example of a Tool
Die for a Board Holder Impact Holder
DF
Reinforcement
Section A - B
DZ
DA
Backer Insert
R
A B B
L
Source: M.Kammerer
alu Example of a Tool
Training in Aluminium Application Technologies Die for a Board Holder Impact 3505.04.03
3505.05 Materials for Impact Tools
Due to the loads and stress levels in impact extrusion tools, the tool materials must have
high strengths, hardness, toughness and wear resistance. For this reason, the material
chosen is always a compromise solution. The most important criteria for the choice of
tool material are:
− Type and magnitude of tool stresses
− Construction and geometry of the tool
− Number of parts to be produced and the required work-piece tolerances
− Toughness and fatigue behaviour
− Wear resistance
− Compressive and tensile strength
− Ease of machining and cost of tool material
Figure 3505.05.01 lists materials for impact tools. Tools for impact extrusion are
mostly made of tool steels. These have the advantages of low material and working
costs as well as high toughness and strength.
TALAT 3505 9
10. Punch
Materials
Material Material No. Hardness HRC
for X 38 CrMoV 5 1 1.2343 52 - 55
Impact X 155 CrVMo 12 1
X 45 NiCrMo 4
1.2379
1.2767
58 - 62
55 - 57
Extrusion S 6-5-2
S 6-5-3
1.3343
1.3344
58 - 64
63 - 65
Tools
Press sleeve
Material Material No. Hardness HRC
X 38 CrMoV 5 1 1.2343 59 - 62
X 155 CrVMo 12 1 1.2379 58 - 62
X 45 NiCrMo 4 1.2767 55 - 57
S 6-5-2 1.3343 60 - 64
S 6-5-3 1.3344 63 - 65
Shrunk-on ring
Material Material No. Hardness HRC
X 38 CrMoV 5 1 1.2343 45 - 56
X 155 CrVMo 12 1 1.2379 54 - 58
X 45 NiCrMo 4 1.2767 47 - 52
Source: IFU Stuutgart
alu
Training in Aluminium Application Technologies
Materials for Impact Extrusion Tools 3505.05.01
Sintered carbides are most suitable when a high wear resistance is required, as is the
case with tools required to produce a large series of parts or with tools having narrow
tolerances.
High speed steel gives a good combination of wear resistance and toughness. According
to one company, high speed steel should not be used for surfaces which come into
contact with light metals during impact extrusion. For these purposes, a 12 % Cr steel
should be used. The 12 % Cr steel has a high hardness retention and strength at high
temperatures and should, therefore, also be utilised for tools which are subjected to high
temperatures.
3505.06 List of Figures
Figure No. Figure Title (Overhead)
3505.01.01 Construction of Impact Extrusion Tools
3505.01.02 Horizontal Toggle-Lever Press
3505.02.01 Design of Punches
3505.03.01 Design of Press Sleeves
3505.03.02 Variations in Construction of Press Die Combination
3505.03.03 Theoretical Distribution of Stress in Press Die Combinations
3505.04.01 Impact Extruded Board Holder
3505.04.02 Example of a Tool: Punch for a Board Holder Impact
3505.04.03 Example of a Tool: Die for a Board Holder Impact
3505.05.01 Materials for Impact Extrusion Tools
TALAT 3505 10