INDUSTRIAL TRAINING REPORT

ON
“CAD WITH SOLIDWORKS”

at

“NSIC TECHNICAL SERVICES CENTRE”

Submitted in partial fulfilment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL & AUTOMATION ENGINEERING

Submitted by
AMRIT KUMAR VERMA E. NO.-00115603620

DEPARTMENT OF MECHANICAL ENGINEERING

DR. AKHILESH DAS GUPTA INSTITUTE OF TECHNOLOGY

FC-26 SHASTRI PARK , NEW DELHI-110053
 Self-Assessment of Industrial Training by Student

1. Student Name: AMRIT KUMAR VERMA

2. Name and Address of Industry: NSIC TECHNICAL SERVICES CENTRE

3. Guide/Trainer from Industry with designation: MR. JEET SINGH

4. Contact details of Guide/Trainer: 9958164196

5. Date of commencement and end: 11/07/2022 TO 09/09/2022

I hereby declare that I have learnt following skills during my Industrial training:
a) CAD
b) SOLIDWORKS
c) GD &T
d) PRODUCT DESIGNING
 Table of Contents

General Introduction

1.1 Introduction to Sheetmetal Fabrication

1.2 What Is Sheet Metal

1.3 Sheet Metal Fabrication

1.4 Sheet Metal Forming Techniques

1.5 Hemming

1.6 Rolling

1.7 Stamping

1.8 Curling

1.9 Metal Spinning

1.10 Advantages of Sheet Metal

1.11 Disadvantages of Sheet Metal

1.12 Applications of Sheet Metal

Chapter - 2
2.1 Sheetmetal Tolerance

2.2 Excessive Forming

2.3 Critical Dimensions

2.4 Standard Tolerance

2.5 Hole Sizes +/- .003” –

2.6 Hole to Hole +/- .005” –

2.7 Hole to Edge +/- .010” –

General

Introduction
1.1 Introduction to Sheetmetal Fabrication
Sheet Metal is a type of material that is flattened into thin sheets. Sheet metal is made by taking a large cast in
and rolling it into a long ribbon of the thickness it wants. This flat metal is rolled into a coil and sent directly
or cut the metal into sheets before being sent to a machine shop.
The sheets are made from different kinds of metals such as aluminum, brass, copper, steel, tin, nickel and
titanium. The sheet’s thickness depends on the material needed for a project. Thicknesses can vary from 0.15
-
6.00 mm significantly; extremely thin sheets are considered foil or leaf, and pieces thicker than 6 mm (0.25 in)
are considered plate steel or “structural steel.”

1.2 What Is Sheet Metal

Sheet metal is one of the shapes and forms metal can be bought in. Sheet metal is any metal that has a
thickness in between 0.5…6 millimeter. Sheet metal is metal formed by an industrial process into thin, flat
pieces. Sheet metal is one of the fundamental forms used in metalworking, and it can be cut and bent into a
variety of shapes. Countless everyday objects are fabricated from sheet metal.

1.2.1 Types Of Sheet Metal

There are six major types of sheet metal material, each with its own unique advantages:

Aluminum
For applications that require a more lightweight material, aluminums are an excellent option. This type of
sheet metal offers significant corrosion resistance even without a finish. Aluminums is also strong and can
undergo laser cutting, welding, and machining.

Grade 3003 is stronger and formable, weldable, corrosion-resistant, and affordable. Grade 5052 is
significantly stronger while still formable, weldable, and corrosion-resistant. Grade 6061 is a structural alloy
that is corrosion-resistant and strong, but not formable. It is weldable, though it sacrifices some strength when
welded.

Alloy Steel
Alloy steel combines multiple elements to enable a customizable set of properties. The main component of
this material is carbon steel. Common additions include tungsten, chromium, and manganese, for rigidity, or
vanadium and nickel, for strength. In addition to its versatility, alloy steel is also highly affordable.
Carbon Steel
Iron is alloyed with carbon in this sheet metal material, providing an option with high amounts of strength.
Depending on the desired application, a manufacturer can choose from steel with low, medium, or high levels
of carbon content.

Tool Steel
Immensely versatile, tool steel is a rigid alloy containing about one percent carbon. As with alloy steel, the
elements contained within tool steel vary in type and ratio depending on the desired application. Tool steel is
resistant to abrasion and functions well in extreme temperatures.

Its properties make this type of sheet metal ideal for the construction of tools, such as punches, dies, blades,
and hammers.

Galvanized Steel
Galvanized steel is available in two varieties: electro-galvanized sheets and hot-dipped metallic-coated sheets.
The former is composed of cold-rolled annealed steel. It has a pure zinc coating with no zinc spangle.

The latter is composed of cold-rolled hard steel plates coated with a mixture of pure zinc and an iron-zinc
alloy. This type of galvanized steel offers more corrosion resistance and is slightly more affordable than
electro-galvanized sheets.

Stainless Steel
This type of sheet metal is ideal for products that will be exposed to frequent moisture. It contains chromium,
an element that significantly reduces corrosion caused by harsh or damp environments. Components made
from stainless steel sheet metal fabrication can increase the lifespan of a product or structure, from kitchen
sinks to office buildings.

1.3 Sheet Metal Fabrication

Sheet metal fabrication is the process of forming metal sheets to the desired shape using different
manufacturing methods. The completion of a product usually comprises of many steps – from cutting and
bending to surface treatment and assembling.
1.3.1 Types of Metal Fabrication Processes
The journey from sheet metal to metal product starts from CAD engineering. After making the models, each
part goes through the necessary sheet metal fabrication processes. The most common ones are:

Laser cutting
Laser cutting is the preferred option for cutting sheet. A very quick and precise cutting method that guarantees
good results. With thicker materials, plasma cutting may be used because of its quickness. This advantage is
only evident with thicknesses upward of 10 mm though.

At the same time, cutting quality favor laser cutting. So, we would advise to rather go with laser cutting
services.

Mechanical Cutting
Shearing, or die cutting, refers to a process that cuts sheet metal without burning or melting it. Also, it does
not produce any chips. In essence, shearing is not too different from cutting with scissors.

In shearing, a punch presses the workpiece against a fixed die or blade. The clearance between is such that
the workpiece does not fit through, causing it to shear. It is a great and cost-effective method to cut sheets
into size whenever complex cuts are not necessary.

Punching
Punching is another way for cutting holes into a sheet. A metal punch hits the sheet, perforating it. It is
suitable for large-scale production but not cost-effective for smaller jobs. The reason lies with the need for a
separate tool for different cuts.

Bending
When it comes to actual engineering, there aren’t many metal components that elude the bending section of a
fabrication shop. Press brakes are responsible for the folding of sheet metal parts.

This is probably the most difficult step in metal manufacturing because of the complexity of some bends. An
engineer must be well acquainted with the limitations of metal bending to things that are actually producible.
Powder coating
Powder coating is a process where an electrostatic powder is applied to a charged metal component. It is the
preferred surface treatment method when no special requirements, like wear-heavy or acidic environments,
apply to the construction.

1.4 Sheet Metal Forming Techniques

Sheet metal forming involves reshaping metal materials while they are still in their solid states. This section
will cover the most important forming processes for sheet metal. These processes are varied in their
applications for making custom fabricated parts.

Bending
Bending is the process that deforms metal with force and bends the metal at the desired angle to form the
required shape. It is carried out with press brakes and rolling machines. A press brake uses a punch and a die
to bend sheet metal. There are different kinds of rolling machines, and they can roll sheet metal into various
shapes within specific ranges.

1.4.1 There are various sheet metal bending methods, and the most common ones
include:
V-bending
Here, the bending punch supplies the force to bend metal materials (placed over the V-die) at desired angles.
This method bends steel plates without changing their position.

Roll bending
This method bends metal sheets into curved shapes or rolls. It uses a press brake, a hydraulic press, and three
rollers to create the desired bend. It is preferred for components like tubes, cones, and other hollow-shaped
materials.

U-bending
This bending process is similar to v-bending. The only differences are that it uses a U-die and the final
components are U-shaped.

Rotary bending
This method bends metals into sharp corners. It is a great choice for bending angles greater than 90 degrees.
Wipe bending

It uses a wipe die to determine the inner radius of the sheet metal’s bend. Generally, bending is ideal for
metals that are malleable but not brittle. They include mild and spring steel, aluminum 5052, and copper.
Materials like aluminum 6061, brass, bronze, and titanium are more difficult to bend.

1.5 Hemming
Hemming involves rolling over a sheet metal edge onto itself to create an area with two layers. It often occurs
in two stages. The first stage involves bending the sheet metal and bottoming it out into a V-die. The second
stage involves the removal of the material and its placement into a flattening die. This process flattens the hem
to give the desired shape.

1.6 Rolling
Sheet metal rolling is the process in which a metal piece passes through a pair of rollers to reduce the
material’s thickness or get a uniform thickness. The rollers are constantly spinning to create compressive
forces that plastically deform the workpiece. If the rollers are directly perpendicular to the piece of sheet
metal, flattening occurs.

1.6.1 There are two major rolling

processes Hot rolling

Hot rolling and cold rolling. Hot rolling occurs above the material’s recrystallization temperature.

cold rolling
Cold rolling usually occurs at room temperature. The common applications of rolled sheet metal are found in
pipes and tubes, stampings, discs, wheels and wheel rims, etc.

Rolling is a fast process with high efficiency, making it suitable for mass production. The process can be
designed to create parts with tight tolerances and complex cross-section profiles. But metal rolling requires
high initial investment, so it’s more suitable for mass production.

1.7 Stamping

Sheet metal stamping is a cold-forming technique that uses stamping presses and dies to transform raw
materials into various shapes. This process is compatible with a wide range of sheet metal materials,
including stainless steel, low- and high-carbon steel, aluminum, brass, copper, etc.

Stamping can generally be a combination of complex cutting and forming techniques to obtain complex
components with shorter operations. It encompasses bending, punching, embossing, and flanging to create an
extensive range of products.
1.8 Curling

Sheet metal curling is the process of adding circular, hollow rolls to sheet metal edges. Most curling processes
occur in three stages; the first two stages create the curves for the curl, while the third stage closes up the curl.

Curls help to remove sharp untreated edges from a workpiece to make it safer for handing. A curled edge also
provides strength to the edge. Curling can also lead to burrs and material deformations, so care must be taken
during the process.

1.9 Metal Spinning

Spinning involves forming metal discs into rotationally symmetrical hollows. During the process, the material
is placed between the tailstock of the machine and a shaped spinning mandrel. Upon rotation, the spinning
roller helps shape the sheet into the shape of the mandrel.

Metal spinning is ideal for mild metal plates, including stainless steel, copper, brass, aluminum, etc. Metal
spinning can produce several hollow parts of various shapes without compromising their quality. Other sheet
metal forming processes like bending and punching can be incorporated into a spinning cycle, making it
highly flexible for both small batch and large volume production. Size and shape limitations are the major
downside to this process. It produces only parts with concentric, symmetric shapes.

1.10 Advantages of Sheet Metal

 Metal fabrication is quite flexible. So even if that toolbox of yours comes out wonky on the first
try, your metal fabricator can bend, snip, and hacksaw it into the shape you want. Metals also have
a higher resistance to heat and are stronger and more durable than, say, plastics.

 Metal fabrication also lends itself to welding, which permanently stabilizes any structure you
want built.

 And if you want to get fancy about it, you can always invest in a laser-guided machine-cutter for
primo accuracy. (And perhaps strain your budget in the process. Better to outsource laser cutting
to a fabricator.

1.11 Disadvantages of Sheet Metal

 Even though metal fabrication is flexible, the viscosity of some metals does not allow them to
be formed into highly complicated shapes or designs.

 Because metal fabrication is generally more labor-intensive, the pieces that you buy
will probably come with a higher price tag.

 For that reason, too, the production process for metal fabrication is generally slower than it is
for, say, metal pressing and stamping. On that note, metal fabrication requires post-fabrication
processes like painting, finishing, and deburring, which can be time-consuming and drive-up prices.
2.1 Sheetmetal Tolerance

Sheet Metal Tolerance

Sheet metal tolerances describe the acceptable deviation between features on sheet metal parts to ensure
correct and consistent fit in installation or integration. As custom mechanicals become more efficient and
requirements more complex, companies demand tighter and more precise tolerances. To achieve a tight
tolerance - at scale- in a fabricated metal part, manufacturers must use state-of-the-art equipment, utilize
robotics & automation where require, and maintain deep industry experience within their highly-skilled labor
force. It is also essential to work with a design-for-manufacturability (DFM or DFX) engineer who has
expertise in sheet metal fabrication during the prototype phase before manufacturing begins.

2.2 Excessive Forming

Incorporating cuts or bends that do not have a functional purpose can create added costs. Excessive forming
can also make the part impossible to bend.

2.3 Critical Dimensions

Always call out information not available on models—datum planes, tolerances (block and critical), material
type, finish requirements, hardware specifications, hole tapping, welding requirements, surface requirements,
and edge requirements, just to name a few.

2.4 Standard Tolerance

Although the machinery and tooling will repeat within .004", it is a mistake to simply engineer all mating
parts, to be within +/-.005". These excess forces additional labor in sorting and inspection. Tolerances that are
too tight result in higher costs and lower productivity. Correct tolerance will still produce excellent fit and
function, with the added benefit of manufacturing efficiency

2.5 Hole Sizes +/- .003” –

The size and shape of the punch and die tooling determine the size and shape of the hole. A minimum hole or
relief size is determined by the thickness of stock to be used. For best results, the punched feature can be no
less than the material being punched. The die tool is slightly larger than the punch to minimize tooling wear
and to reduce the pressure required to punch the hole. Generally speaking, 10% of the material thickness is
used for most applications. For example, if the material is .100” aluminum and the punch diameter is 1.000”,
the die diameter would be 1.010”. The size of the hole on the punch side will be the same size as the punch
tool. The size of the hole on the die side will be the same size as the die tool. Except for tooling wear, there is
very little variation from one hole to the next. Generally speaking, +/-.003” is a reasonable and functional
tolerance.

2.6 Hole to Hole +/- .005” –

Accuracy of the distance from one hole to another is dependent primarily upon the machinery used to process
the sheet. Some equipment will hold better than +/-.005” with little difficulty. However, all holes and features
punched through the sheet can introduce stress into the sheet metal. If the part has a closely spaced perforated
pattern or formed features such as dimples or counter sinks, the result can cause the sheet to warp and distort.
This can cause unwanted variation between holes or features.
2.7 Hole to Edge +/- .010” –
Part profiles are punched just like any other feature, except when using a machine with shearing capabilities.
These dimensions should be considered the same as hole-to-hole. When punching close to an edge (less than
double the material thickness), the edge can be pushed out by the stress of punching the metal. This edge
movement can introduce variables in the accuracy of the hole location in relation to the edge. There are
techniques to minimize this problem, but whenever possible, engineers should allow +/-.010” hole-to-edge.
Tolerances of +/-.005” should be used only when absolutely necessary.

2.8 Hole to Bend +/- .015” –

Severalfactors have been introduced leading up to this stage in the fabrication process. Features and parts have been
punched on a CNC turret press, line sanded or tumbled to remove burrs, and is now being formed on a press brake.
The deburring process may remove .003” when cosmetic appearance is a priority.

2.9 Bend to Bend +/- .020” –

Considering the variables that affect hole-to-bend tolerances, now multiple material surfaces and thickness
are introduced. Whenever possible, engineers should allow +/-.020” bend-to-bend. Resort to +/.010” only
when absolutely necessary. Increased tolerances need to be applied if going across multiple bends.
 Sheet metal defects

3.1 INTRODUCTION To Sheetmetal Defects

Like any other technically demanding environment, sheet metal productivity suffers from an occasional

hiccup or two. There are numerous quality-assurance standards for managing the equipment and their raw

materials, but errors crop up from time-to-time. Look at those mistakes as an opportunity to learn, to

improve the process and make the line more efficient. Having incorporated that glass-half-full mindset, let’s

identify some common sheet metal defects

3.2 Wrinkles
Generally, if experiencing wrinkles during production, this could mean the wrong process was chosen to
manufacture the part or a key process parameter (such as binder force) could be incorrect. Wrinkles occur
when the sheet metal stamping process produces compressive strains that “push” material together, causing
the material to overlap each other in the worst case. A thicker material resists the compressive forces more
so than a thinner material – speaking broadly – and thus a thin material will wrinkle more easily.

Wrinkles can often be solved by stretching or drawing material, instead of forming or “crushing” without any
pads/binders restraining the flat sheet. However, for more complex 3D shapes, in addition to pads/binders,
draw beads may be required to initiate maximum stretch in the material and prevent it from wrinkling.

The negative impact of removing wrinkles can be use of more material than just the net part shape, as flat
material is needed to clamp and stretch the wrinkles out, which later is cut off as scrap. However, the cost of
scrap may be insignificant compared to a serious process defect which may lead to rejected parts in
production.

3.3 Sheet Metal Splits

A series of wrinkles is growing and propagating. The layers of metal are being pushed past their workability
limits, to the point the sheet metal is beginning to thin. Stretching and thinning, the flat layer tears along the
weakest area. Known as “necking,” this phenomenon is common, so it can be addressed quickly and resolved
before the entire production run is jeopardized. Forming simulation software is often used to analyze this
common sheet deformation error. Alternatively, examine the form radius and depth settings, material type
and thickness, applied heat treatment techniques, and ensure a forming limit diagram is incorporated into the
design phase of the process.
3.4 High-Strength Material Spring back
In this defect example, the desired shape isn’t being accommodated because the bend radius is falling below
the set value, as imposed by the bending equipment. An overbend or overcompensation adjustment corrects
this particular issue. If that action doesn’t bring the elastic deformation error under control, positive stretching,
a stage that increases part stiffness, will correct the bend angle miscalculation. The problem exists in the high-
strength material’s stress-to-strain curve.

All of these solutions yield superior results. However, they require finite adjustments, so waste workpieces
are unavoidable. If wastage is an unallowable notion, and it often is in a tightly run engineering environment,
then the mastery of a top-flight piece of fabrication simulation software is desirable. By inputting the material
type, thickness, and other material parameters, the production managers can simulate different bends and
compressive forces without ever wasting a single sheet metal section.

3.5 Cambering
Cambering happens when there is a variation of sheet thickness along with its width. This defect happens
when the work piece moves horizontally with no twist, resulting in convex, concave and triangular shaped
material. Being one of the common shearing mistakes, operators try to minimize it at the early stage by
shifting the grain directions of materials and by adjusting the rake angle of the work piece.
4.9 Drawing Sheet
4.10 Drawing Sheet