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SHEET METAL PROCESS

1. Sheet Metal Forming Process Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking, and can be cut and bent into a variety of different shapes. The raw material for sheet metal manufacturing processes is the output of the rolling process. Typically, sheets of metal are sold as flat, rectangular sheets of standard size. If the sheets are thin and very long, they may be in the form of rolls. Therefore the first step in any sheet metal process is to cut the correct shape and sized blank (The sheet metal part before it is bent) from larger sheet. Sheet metal processes can be broken down into two major classifications and one minor classification: Shearing processes: Shearing is similar to the process by which someone cut a sheet of paper using scissors. Thus, It is process which apply shearing forces to cut, fracture, or separate the material. Forming processes: processes which cause the metal to undergo desired shape changes without failure, excessive thinning, or cracking. This includes bending and stretching. Finishing processes: processes which are used to improve the final surface characteristics. 1. Shearing Process 1. Punching: shearing process using a die and punch where the interior portion of the sheared sheet is to be discarded. 2. Blanking: shearing process using a die and punch where the exterior portion of the shearing operation is to be discarded. 3. Perforating: punching a number of holes in a sheet 4. Parting: shearing the sheet into two or more pieces 5. Notching: removing pieces from the edges 6. Lancing: leaving a tab without removing any material 2. Forming Processes Bending: forming process causes the sheet metal to undergo the desired shape change by bending without failure. Stretching: forming process causes the sheet metal to undergo the desired shape change by stretching without failure. Drawing: forming process causes the sheet metal to undergo the desired shape change by drawing without failure.

Roll forming: Roll forming is a process by which a metal strip is progressively bent as it passes through a series of forming rolls.

3. Finishing processes Material properties, geometry of the starting material, and the geometry of the desired final product play important roles in determining the best process.

Classification of Manufacturing Process Overview

Manufacturing process are divided into two major operations: 1. processing operations: transform a work material from one state of completion to a more advanced state. It is operations that change the geometry,properties, or appearance of the starting material. 2. assembly operations: join two or more components to create a new entity processing operations. There are three categories of processing operations: 1. Shaping operations: alter the geometry of the starting work material 2. Property-enhancing operations: improve physical properties without changing shape 3. Surface processing operations: to clean, treat, coat, or deposit material on exterior surface of the work Shaping process are divided into four groups: 1. Solidification processes: starting material is a heated liquid or semifluid 2. Particulate processing; starting material consists of powders 3. Deformation processes; starting material is a ductile solid (commonly metal) 4. Material removal processes; starting material is a ductile or brittle solid

Solidification process Starting material is heated sufficiently to transform it into a liquid or highly plastic state Examples: metal casting, plastic molding Particulate processing starting materials are powders of metals or ceramics. Usually involves pressing and sintering. Deformation process Starting workpart is shaped by application of forces that exceed the yield strength of the material Examples: forging, extrusion Material removal process Excess material removed from the starting piece so what remains is the desired geometry Examples: machining such as turning, drilling,and milling also grinding and nontraditional processes Property enhancing process Performed to improve mechanical or physical properties of work material. Part shape is not altered, except unintentionally Example: unintentional warping of a heat treated part Examples: Heat treatment of metals and glasses, Sintering of powdered metals and ceramics Surface processing operations Cleaning chemical and mechanical processes to remove dirt, oil, and other contaminants from the surface Surface treatments mechanical working such as sand blasting, and physical processes like diffusion Coating and thin film deposition -coating exterior surface of the workpart

Assembly operations are divided into two groups:

1. The permanent joint: it cant be removed except by destroying it first Example: welded joint, soldering, and adhesive bonding 2. The mechanical joint such as tightening the screw (screw, nuts, bolts), and tightening of the permanent (rivet,press fitting)