Engineering Manufacturing Lab Report

Industrial visit report

Rayyan Enterprise

Submitted by: Waqas Ibrahim

Registration No.: 2018-UET-NFC-FD-MECH-49
Section: B
Semester: 3rd
Submitted to: Dr. M. Arif

DEPARTMENT OF MECHANICAL ENGINEERING

NFC-IEFR FAISALABAD
Nov,2019
 Layout of Rayyan Enterprises

Hydraulic Press Machine

Cutter Knife

Arc Welding Plant

Mechanical Press Machine 01 Disc Cutter

Mechanical Gas Welding

Press Plant
Machine 02
 Introduction
Rayyan Enterprise

Hydraulic press machine:

A hydraulic press is a machine press using a hydraulic cylinder to generate a
compressive force. It uses the hydraulic equivalent of a mechanical lever. A machine
pressing tool for bending sheet and plate material, most commonly sheet metal. It forms
pre-determined bends by clamping the work piece between a matching punch and die.

Cutter Knife:
Cutter knife is a machine which we use for the cutting of long and thin sheets.
Cutter knife produce shearing force on a sheet and provide a very fine surface. Because
sheet have long lengths so to cut at desired length we use cutter knife to cut the sheet.

Mechanical press machine:

Any machine that exerts pressure to form or shape or cut materials is
basically called a mechanical press machine. The basic principle of the mechanical
press is to convert the circular motion into a linear motion. In Rayyan Enterprises we
saw three mechanical press machines in which two machines are working with two
different loads.

Gas welding plant:

Gas welding is a welding process that melts and joins metals by heating them
with a flame caused by a reaction of fuel gas and oxygen. The most commonly used
method is Oxyacetylene welding, due to its high flame temperature. Gas welding plant
contain two cylinders colored black and brown. The black cylinder contains oxygen
while brown cylinder contains oxyacetylene.

Arc welding plant:

Arc welding is a welding process that is used to join metal to metal by using
electricity to create enough heat to melt metal, and the melted metals when cool result
in a binding of the metals.

Disk Cutter:
A disk cutter is basically a hand held machine which is used for cutting. We have
seen disk cutter in Rayyan enterprise. They use disk cutter for sheet cutting process. A
disk is basically a device which is used in disk cutter. The disk rotates at very high speed
due to which the sheet can be cut easily.
 Experiment no. 01
Punching and Blanking

Punching
Punching is a forming process that uses a punch press to force a tool, called a
punch, through the work piece to create a hole via shearing. Punching is applicable to a
wide variety of materials that come in sheet form, including sheet metal, paper,
vulcanized fibre and some forms of plastic sheet. The punch often passes through the
work into a die. A scrap slug from the hole is deposited into the die in the process.
Depending on the material being punched this slug may be recycled and reused or
discarded.
It’s called “punching” because it involves punching a hole through a work piece.
It can be performed either by hand or using a machine, the latter of which is preferred
as it’s able to forcefully drive holes through thick, hard metals.

Why we use Punching?

Punching is often the cheapest method for creating holes in sheet materials in
medium to high production volumes. When a specially shaped punch is used to create
multiple usable parts from a sheet of material the process is known as blanking. In metal
forging applications the work is often punched while hot, and this is called hot
punching. Slugging is the operation of punching in which punch is stopped as soon as
the metal fracture is complete and metal is not removed but held in hole
Working Principal of Punching:
In the past, punching was performed by hand. Hand-punching tools are still
available and they are still used by some companies and individuals but most punching
now performed using a machine. Powered by hydraulic pressure, the machine forces
the punching tool onto and through the work piece. Below the punching press is a die
block in the desired shape of the hole. As the punching press pushes through the work

piece, it leaves behind a hole in the shape of the die.

As explained above, punching operation removes scrap from the larger piece of
sheet metal. It is a metal removal operation. As a result of punching, larger piece of
sheet metal becomes final product.

Press punching Machine

 This is manual punching press machine which we have seen in Rayyan
enterprises. Name of each part of that machine is explained in above picture. The force
is applied manually with the help of the foot switch. In result of force the punch in
produced in the sheet.

Difference between Drilling and punching

Punching operation removes scrap from the larger piece of sheet metal. It is a
metal removal operation. As a result of punching, larger piece of sheet metal becomes
final product.
Quicker
The hand-held punching machine is much quicker than using a drill as there is no need
to spend time making pilot holes prior to using it. All you need to do is mark where
your hole needs to be, set the depth gauge and punch away.

Neater than drilling

If done correctly, punching a hole in a sheet material is nearly always neater than using
a drill. Drills have a tendency to vibrate, wobble and tear at material, increasing the
likelihood of the drill bit wandering or making a non-circular hole. Punching machines
don’t have this problem.
Blanking
Blanking and piercing are shearing processes in which a punch and die are used
to modify webs. The tooling and processes are the same between the two, only the
terminology is different: in blanking the punched out piece is used and called a blank;
in piercing the punched out piece is scrap. The process for parts manufactured

simultaneously with both techniques is often termed "pierce and blank." An alternative
name of piercing is punching.

Characteristics of blanking process:

 Its ability to produce economical metal work pieces in both strip and sheet metal
during medium or high production processes,
 The removal of the work piece from the primary metal stock as a punch enters a
die,
 The production of a burnished and sheared section on the cut edge,
 The production of burred edges,
 The control of the quality by the punch and die clearance,
 The ability to produce holes of varying shapes – quickly.
Fine blanking process
Fine blanking process is one the specialize type of process. Which blanking
process sheared the sheet metal in three type of force separately applied. The fine
blanking provides parts having smooth edge better flatness and high tolerance. It ranges
from ± 0.0003. It can be make high quality parts without any secondary operation
require. But that require tools and additional equipment for making high volume
production with better suited.
It tools and equipment very similar to conventional blanking operation. The sheet
stock is placed on the blanking die with hydraulic press and then the punch impacts the
sheet metal to remove blank parts. During the process the part done by 3 type of force
applied.
First force
First force is downward force apply to top of sheet metal. That is act as holding
force during the process. The clamping force holds a guide plate with tightly then again
the sheet metal holds in placed an impingement ring. It is called stinger.
Second force
First force is downward force apply to top of sheet metal. That is act as holding
force during the process. The clamping force holds a guide plate with tightly then again
the sheet metal holds in placed an impingement ring. It is called stinger.
Third force
It force applied by the blanking punch impact the sheet metal and sheared the
blank into die opening. The clearance provided in between punch and die the range of
0.001 inches. The blanking operation perform at slowly. The metal fracturing into free
the blank then blank flow is extruded to provide a smooth edge of blank.
Blanking press
Blanking press is the machine which we have seen in Rayyan Enterprises. This
blanking press is used to make a blank in sheet metal. The image of the blanking press
is shown below.

)
 Experiment no. 02
V-Bending
Bending
Bending of sheet metal is a common and vital process in manufacturing industry.
Sheet metal bending is the plastic deformation of the work over an axis, creating a
change in the part's geometry. Similar to other metal forming processes, bending
changes the shape of the work piece, while the volume of material will remain the same.
In some cases, bending may produce a small change in sheet thickness. For most
operations, however, bending will produce essentiallly no change in the thickness of the
sheet metal. In addition to creating a desired geometric form, bending is also used to

impart strength and stiffness to sheet metal, to change a part's moment of inertia, for
cosmetic appearance and to eliminate sharp edges.

Bending Process
Bending processes differ in the methods they use to plastically deform the sheet
or plate. Work piece material, size and thickness are important factors when deciding
on a type of metal bending process. Also important is the size of the bend, bend radius,
angle of bend, curvature of bend and location of bend in the work piece. Sheet metal
process design should select the most effective type of bending process based on the
nature of the desired bend and the work material. Many bends can be effectively formed
by a variety of different processes and available machinery will often determine the
bending method.
Sheet metal V-Bending
One of the most common types of sheet metal manufacturing processes is V bending.
The V shaped punch forces the work into the V shaped die and hence bends it. This
type of process can bend both very acute and very obtuse angles, also anything in
between, including 90 degrees.

Working Principle of V-Bending.

The V-die bending process is the bending of a V-shaped part in a single die. The
principle of the V-die bending process. The work piece is bent between a V-shaped
punch and die. The force acting on the punch causes punch displacement and then the
work piece is bent. The work piece is initially bent as an elastic deformation. With
continued downward motion by the punch, plastic deformation sets in when the stresses
exceed the elastic limit. This plastic deformation starts on the outer and inner surfaces
directly underneath the punch.
The greatest tensile stress is generated on the outer surface, whereas the greatest
compressive stress is generated on the inner surface; these stresses decreasingly
propagate inward toward the work piece. Therefore, crack formation usually occurs on
the outer surface and a wrinkle usually occurs on the inner surface. The initial bending
stage—the so-called “Air bending”—starts the moment the punch establishes contact
with the work piece and is completed either when the legs of the work piece become
tangential to the faces of the die or when the smallest internal radius of the work piece
becomes smaller than the radius of the punch. As the process continues, after
completion of air bending, the bending is focused on the three points of the punch and
the two faces of the die. The contact points between the work piece and die are shifted
toward the centreline of the die, and the legs of the work piece try to close around the
punch. The clearance between the punch and the die in V-die bending is commonly
dependent of the work piece thickness. The usual thickness of the work piece in the V-
die bending process ranges from approximately 0.5 to 25 mm.

Hydraulic Bending Machine

Hydraulic bending machine or Brake bending machine is basically a hydraulic press
machine which we have seen in Rayan enterprises. With help of this machine we have
seen there they performing the V-Bending operation.
With help of brake press the force is applied at the specific angle on the sheet which
results in the V-bending. So with the help of Brake bending machine we can perform
sheet metal bending easily.
Bend Force
Bend force is the force required to cause a sheet metal to bend at an angle and form the
desired shape. Bend force depends on the maximum external bending moment which
consists of two elements:
 The bending moment due to bend force and punch travel
 The additional moment to overcome the friction around the die shoulders.
Bend force is influenced by sheet metal properties (thickness, tensile strength, strain
hardening exponent, strength coefficient), the tool parameters (punch radius, die radius,
die width), the process parameters (punch displacement, bending angle) (Wang et al
1993). Bend force can be estimated by assuming the process as a simple beam bending

Classification of V-die Bending Process

The basic advantages of the V-die bending process are as follows:
 a simple tool design,
 an economical setup time, and
 an enormous range of sizes and complex shapes that can be fabricated for the
part.
Therefore, the V-die bending process is generally used in both the Press Brake
machine and the Press machine associated with press-form tooling. However, the basic
disadvantage of the use of the Press Brake machine is low productivity. The Press Brake
machine is suitable for production of only a small quantity or the prototype of a product.

Drawbacks in V-die bending process

Considering the accuracy of the produced part, the product in the sheet metal–forming
process is set higher requirements consisting of precise dimensions. These consist of
fundamentally the same requirements as for the V-die bending process. Unwanted
deformation generally occurs in the bending zone (underneath the punch), especially,
the thick part of the work piece and sharp bends, which results in a decrease in the
accuracy of the part.
As mentioned above, the principle of the V-die bending is not very difficult to
understand; however, a great degree of expertise and skills are required as this is an
important technique for increasing the productivity and for improving product quality.
Therefore, the characteristic features of bending must be theoretically understood. In
addition, the effects of the process parameters related to the geometry and properties of
the material must be strictly considered to achieve high-quality bent parts.