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Report On Sheet Metal Fabrication PDF
Report On Sheet Metal Fabrication PDF
ON
AT
The knowledge of Sheet Metal Fabrication is very useful in our day-today life and one needs to know at least the basics of the same. The content of
this report includes an overview about the whole manufacturing
fundamentals and the processes to be followed in this category in order to
obtain the required final product.
The report contains the description of various processes to be followed
and their analysis for their better understanding. The various processes
included in the report are the Shearing, Punching (CNC & LASER), Bending,
Welding, Grinding and Powder Coating Processes. The operation study,
machine study, and material information are clearly mentioned out there.
At the end of the report, there is also a portion of future scope, in
which some drawbacks and improvements needed, can be acknowledged. In
last words, this report is all about the industrial aspect related to sheet metal
fabrication.
M.A.K. Pathan
M. Anzar Sareshwala
INDEX
Sr.
No.
Name of Chapter
Page
No.
Introduction of Company
Literature Survey
Practical Sessions
25
Conclusion
30
List of Figures
Fig.
No.
Name of Figure
Page No.
2.1
Shearing process
2.2
Shearing machine
2.3
Punching process
10
2.4
11
2.5
Punched workpieces
12
2.6
Blanking process
12
2.7
Blanked workpieces
13
2.8
Nibbling
13
2.9
14
2.10
16
2.11
Flange specimen
16
2.12
Hydraulic press
17
2.13
19
2.14
19
2.15
20
2.16
20
2.17
21
2.18
Portable grinder
22
2.19
Grinding a bar
22
2.20
Spray coating
23
2.21
Bending specimen
24
3.1
Work Flowchart
29
Nomenclature:
M.S. Mild Steel
S.S. Stainless Steel
CNC Computer Numerical Control
TIG Tungsten Inert Gas
MIG Metal Inert Gas
Ch. 1
Introduction of Company
A. Name:
Ch. 2
Literature Survey
This is a modern shearing machine that can be used to cut the sheets with a
smoother operation and high accuracy. The shearing tool imparts the force
hydraulically and the operating pedal works pneumatically. The gauge size
can be set with a program to cut bars of specific size from a larger sheet.
There are supporting anvils for longer sheets. The shearing tool is mounted a
bit inclined to x-axis, as to produce trimming effect and to avoid bending of
sheet due to single stroke.
9
PUNCHING PROCESS:
Punching is a metal fabricating process that removes a scrap slug from the
metal workpiece each time a punch enters the punching die. This process
leaves a hole in the metal workpiece.
CNC Punching and Blanking:
Punching is the process of forming metal components using a punch. The
punch is usually the upper member of the complete die assembly and is
mounted on the slide or in a die set for alignment (except in the inverted
die).
The punching process forces a steel punch, made of hardened steel, into and
through a workpiece. The punch diameter determines the size of the hole
created in the workpiece.
The
illustration
that
follows
provides a two-dimensional look at
a typical punching process. Note
how the workpiece remains and the
punched part falls out as scrap as
the punch enters the die. The scrap
drops through the die and is
normally collected for recycling.
10
11
burnish
burr
fracture
roll-over
12
The limitations for CNC turret: Maximum limit for various materials:
Aluminium- 5mm, Mild steel- 3mm, Copper- 4mm and Brass- 3mm.
Continuous cooling is required for proper and safe operation. An oil tank is
also used to provide oil for extensive lubrication that is necessary to avoid
wear of job and tool. Mostly all jobs can be done on CNC for punching
purpose, but there are some limitations of it, due to which there arises the
need of Laser CNC machine.
13
Laser Punching:
Laser cutting machines can accurately produce complex exterior contours.
The laser beam is typically 0.2 mm (0.008 in) diameter at the cutting surface
with a power of 1000 to 2000 watts.
Laser cutting can be complementary to the CNC/Turret process. The
CNC/Turret process can produce internal features such as holes readily
whereas the laser cutting process can produce external complex features
easily.
Laser cutting takes
direct input in the
form of electronic data
from a CAD drawing
to produce flat form
parts
of
great
complexity. With 3axis control, the laser
cutting process can
profile parts after they
have been formed on
the
CNC/Turret
process. Lasers work
best on materials such as carbon steel or stainless steels. Metals such as
aluminum and copper alloys are more difficult to cut due to their ability to
reflect the light as well as absorb and conduct heat. This requires lasers that
are more powerful.
Lasers cut by melting the material in the beam path. Materials that are heat
treatable will get case hardened at the cut edges. This may be beneficial if
the hardened edges are functionally desirable in the finished parts. However,
if further machining operations such as threading are required, then
hardening is a problem.
14
A hole cut with a laser has an entry diameter larger than the exit diameter,
creating a slightly tapered hole.
The minimum radius for slot corners is 0.75 mm (0.030 in). Unlike blanking,
piercing, and forming, the normal design rules regarding minimum wall
thicknesses, minimum hole size (as a percent of stock thickness) do not
apply. The minimum hole sizes are related to stock thickness and can be as
low as 20% of the stock thickness, with a minimum of 0.25 mm (0.010 in)
upto 1.9 mm (0.075 in). Contrast this with normal piercing operations with
the recommended hole size 1.2 times the stock thickness.
Burrs are quite small compared to blanking and shearing. They can be
almost eliminated when 3D lasers are used and further, eliminate the need
for secondary deburring operations.
As in blanking and piercing, considerable economies can be obtained by
nesting parts, and cutting along common lines. In addition, secondary
deburring operations can be reduced or eliminated.
The limits associated with laser cutting Maximum sheet thickness
preferred: Aluminium- 1 mm, Mild steel- 8mm, Stainless Steels- 6mm.
The laser first penetrates the job at specific point, then moves to the
boundary of loop and forms the cut as per design. The laser moves in X and
Y direction to get desired job. This motion is called as interpolation.
There is a cooling water system comprising of two heat exchangers that
maintains the temperature of internal portion of machine where much heat
is generated during laser emission.
The main characteristic of Laser cutting is that no finishing operation is
required on the job as directly finished job is obtained.
15
BENDING PROCESS:
Bending is a process by which metal can be deformed by plastically
deforming the material and changing its shape. The material is stressed
beyond the yield strength but below the ultimate tensile strength. The
surface area of the material does not change much. Bending usually refers to
deformation about one axis.
Bending is a flexible process by which many different shapes can be
produced. Standard die sets are used to produce a wide variety of shapes.
The material is placed on the
die, and positioned in place
with stops and/or gauges. It is
held in place with hold-downs.
The upper part of the press, the
ram with the appropriately
shaped punch descends and
forms the V-shaped bend.
Bending is done using Press
Brakes. Press Brakes normally
have a capacity of 20 to 200 tons to accommodate stock from 1m to 4.5m (3
feet to 15 feet). Larger and smaller presses are used for specialized
applications. Programmable back gauges, and multiple die sets available
currently can make for a very economical process.
The minimum flange width should be at least 4 times the stock thickness
plus the bending radius. Violating this rule
could cause distortions in the part or
damage to tooling or operator due to
slippage.
16
The machine has a stationary bed or anvil and a slide (ram or hammer)
which has a controlled reciprocating motion toward and away from the bed
surface and at right angle to it. The slide is guided in the frame of the
machine to give a definite path of motion.
A form of open-frame single-action press that is comparatively wide between
the housings, with a bed designed for holding long, narrow forming edges or
dies. Used for bending and forming strip, plate, and sheet (into boxes,
panels, roof decks, and so on).
Dies used in presses for bending sheet metal or wire parts into various
shapes. The work is done by the punch pushing the stock into cavities or
depressions of similar shape in the die or by auxiliary attachments operated
by the descending punch. Various types of machinery equipped with two or
more rolls to form curved sheet and sections.
17
WELDING PROCESS:
Welding is the process of permanently joining two or more metal parts, by
melting both materials. The molten materials quickly cool, and the two
metals are permanently bonded.
Mainly used welding types are Argon (TIG) welding and MIG welding.
TIG welding:
TIG welding is a slower process than MIG, but it produces a more precise
weld and can be used at lower amperages for thinner metal and can even be
used on exotic metals. TIG welding is a commonly used high quality welding
process. TIG welding has become a popular choice of welding processes
when high quality, precision welding is required. The TIG welding process
requires more time to learn than MIG.
Characteristics:
18
The illustration that follows provides a schematic showing how the TIG
welding process works.
MIG welding:
The "Metal" in Gas Metal Arc Welding refers to the wire that is used to start
the arc. It is shielded by inert gas and the feeding wire also acts as the filler
rod. MIG is fairly easy to learn and use as it is a semi-automatic welding
process.
19
Welding gun
GMAW torch nozzle cutaway image: (1) Torch handle,
(2) Molded phenolic dielectric (shown in white) and
threaded metal nut insert (yellow), (3) Shielding gas
diffuser, (4) Contact tip, (5) Nozzle output face
Characteristics:
The illustration that follows provides a look at a typical MIG welding process
showing an arc that is formed between the wire electrode and the workpiece.
During the MIG welding process, the electrode melts within the arc and
becomes deposited as filler material. The shielding gas that is used prevents
atmospheric contamination
from
atmospheric
contamination and protects
the
weld
during
solidification. The shielding
gas
also
assists
with
stabilizing the arc which
provides a smooth transfer of
metal from the weld wire to
the molten weld pool.
Versatility is the major
benefit of the MIG welding
20
lap joint
butt joint
T-joint, and the
edge joint
MIG is used to weld many materials, and different gases are used to form the
arc depending on the materials to be welded together. An argon CO2 blend is
normally used to weld mild steel, aluminum, titanium, and alloy metals.
Helium is used to weld mild steel and titanium in high speed process and
also copper and stainless steel. Carbon dioxide is most often used to weld
carbon and low alloy steels. Magnesium and cast iron are other metals
commonly welded used the MIG process.
GRINDING PROCESS:
Grinding is a finishing process used to improve surface finish, abrade hard
materials, and tighten the tolerance on flat and cylindrical surfaces by
removing a small amount of material. In grinding, an abrasive material rubs
against the metal part and removes tiny pieces of material. The abrasive
material is typically on the surface of a wheel or belt and abrades material in
a way similar to sanding. On a microscopic scale, the chip formation in
grinding is the same as that found in other machining processes. The
abrasive action of grinding generates excessive heat so that flooding of the
cutting area with fluid is necessary.
21
22
23
Analysis:
Bending process:
The bending force for sheet metal in Vdies,
Eg:
For bending a 1 inch thick and 10 inch broad M.S. Sheet of 70 ksi. tensile
strength is to be bend with a V-die of opening 3 inch then the bending
force is :
Su = 70 ksi.
W= 10 in.
t = 1 in.
L = 3 in.
As
F = 310.33 KN
24
Ch. 3
Practical Sessions
Our whole training session was divided in two Departments, half of which in
Design Department and the other half in Production Department.
Design
The ordered jobs to be made are received by the industry in the form of
their drawings on paper or Adobe files. These drawings are firstly studied by
the Design Department regarding the type of the material required by the
ordering company, the possiblity of the job to be made well with that type of
material, the amount of material required in accomplishing the task, the
type operations to be performed on respective machines, etc.
The industry follows the following fixed sequence for the completion of
the task regarding the design part:
Detailed study of the drawing
Development of the drawing
Part List
DXF file is made for RADAN software used for punching purpose
25
For example, if the thickness of the sheet as per order is very small and
the processes to be carried out on it are complex, then to produce such a job
is very difficult or one can regret the order if the sufficient facilities are not
available in the industry.
Then the drawing is developed by unfolding it so that the quantity of
the material or the size of the sheet can be known. An allowance is also
considered in the development so as to get the exact size as required on
order. The following are the allowances to be considered for the respective
sheet thicknesses:
Sheet Thickness
Allowance
3.0
2.5
2.0
1.6
1.2
1.0
2.5
2.0
1.6
1.3
1.1
1.0
Table 3.1
26
Production
The designs dept. feed the input to the prod. dept. It provides the finalised
drawing and the part list. This part list is then used to get the results for
optimise use of available raw material with the help of a software, Plus 2D. It
give the effective productivity on the basis of raw material and parts.
Minimum criteria followed here is 92 % overall.
According to mentioned sequence, the first stop is shearing. The operator is
given a drawing or just the figure of final dimensional of sheet that is
required of raw material for jobwork. The worker prepare the specific blank
sheet for further processing.
We saw the operation of the shearing machine and its observed the
precautions to be taken. Also studied the mechanism of the mechanism just
by observing as we were not authorized to operate it. But the presence of
mind made it easier to grasp the process funda and the style of the operator.
The sheet is then either fabricated under CNC turret or Laser machine under
various circumstances. For CNC work, the CNC operator is given a notepad
file via network. He manipulate various parameters and sets the tool and die
combinations as per mentioned in the file. Then as the computer is
connected to CNC, the CNC reads the required job file and the operator
initiates the process of punchng in CNC. The accomplished job requires
grinding and finishing.
The CNC machine was the most fascinating machine to observe, the
operator told us about the program manipulating and its relation to the tool
sequence in turret of CNC. We saw the mounting of die and punch
combinationsfor punching purpose. There is a neutral indicating point at
whiah job is to be fixed, in order to get the perfect output.
For Laser process, the operator is provided with a .dxf file that he used to
generate a a program file for Laser input with a flopppy disk. The job is then
fixed on the table at neautral point according to axes. The operator initiates
the machine work, Laser automatically arrange the sequence of various
27
cuttings in job. The finishing of job is not required cause of good quality
cutting and deburred edges.
The job then moves to the bending shop. Here the operator understands the
job and its diagram to carry on the required process. The symbols like BUP
and BDN shows about the direction of bend to be applied on job. The
operator sets the feed into CNC bending machine (Press Brake), and arrange
the suitable punch and die for the required job. The job is then set onto the
bolster against the gauge that maintains the simension of a portion of sheet
to be bend. The final job is then proceeded for further operations.
We acknowledged the importance of press brake.It was intresting to
watch the operation of the bending machine as around 100 tons of force is
applied to make the sheet at right angle or some specific angle.
The job is taken to the welding area. The job and its edges are properly
cleaned to avoid any inclusions at the time of welding. The job is then kept
on an anvil or support frame to weld. The bend edges ar then welded by MIG
or Argon welding.The job is then left idle to get cooler.
The job is further proceeded for grinding process. Here the edges and the
weld portioned is grinded with the help of grinder with abrasive wheel the
remove the burr off the edges. Also the the weld foul appearance is improved
a lot by this grinding processes.
The job is then moved on for final coating. Generally the powder coating is
done to give it durable outer membrane. This process increase the corrosion
resistance and the life of the material. Mostly the various types of finish in
powder coating are done on customer demands.
It was great to watch the whole process of fabrication for a shhet material
upto ready enclosure or panel (Job). The fixed sequence of observing helped
us to uderstand the pros and cons of various process.
28
29
Ch. 4
Conclusion
30