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MANUFACTURING PROCESS. Unit -3. Prof. Kiran Gore. Contents. Casting Metal forming process ( Forging ) Sheet metal working Metal joining process. Sheet metal working. Sheet metal working.
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MANUFACTURING PROCESS Unit -3 Prof. Kiran Gore
Contents • Casting • Metal forming process ( Forging ) • Sheet metal working • Metal joining process
Sheet metal working • Is the process of manufacturing the components or parts from the sheet metal of thickness ranging from 0.1 to 10 mm • The sheet metal working is generally carried out with the machine tools called as press.
P R E S S
P R E S S
APPLICATION • The vehicle parts like doors, roofs, fuel tanks, front guards etc. Can be produced by sheet metal working (press working) • Aircraft industry, radio & telephone industry, electrical parts.
Metal cutting operations(Shearing operation ) Metal cutting operation include • Punching • Piercing • Blanking • Notching • Perforating • Shaving • Shearing
1. Punching It is the cutting operation with the help of which holes of various shapes are produced in the sheet metal.
PUNCHING punch-out: scrap remaining strip: work piece
2.Piercing • Piercing is the operation of producing a hole of any desired Shape in a metal by using punch & die. • In piercing , the metal sheet with the hole is the required component while the material punched out to form the holes is the waste part.
3)Blanking:- • Blanking is the cutting operation of a flat metal sheet & the article punched out is known as blank. • Blank is the required product of the operation & the metal left behind is considered as a waste.
B L A N K I N G
Blanking and Punching (a) Blanking (b) punching
4) Notching • It is similar to blanking operation but in this full surface of punch does not cut the metal. • In this operation metal pieces are cut from the edges of a sheet.
4) Perforating • It is similar to piercing but the difference is that to produce holes is not of the round shape. • In this process multiple holes which are very small and close together are cut in the sheet metal.
5) Shaving:- • This operation is used for cutting unwanted excess material from the periphery of a previously formed work piece. • In this process very small amount of material is removed.
6)Shearing:- • It is an operation through which a metal is cut along a single line. • Which is generally is a straight line.
Metal forming operation Metal forming operations include following operations • Bending • Drawing • Embossing • Coining
1. Bending • It is a metal forming operation in which the straight metal sheet is transformed into a curved form.
The bending methods which are commonly used are as follows a) V Bending b) U Bending c) Angle bending d) Curling
2) Drawing / Forming • Drawing is the process of shaping a flat metal sheet into a surface of a desired profile. • In this process the shape of the punch & die is directly reproduced.
Drawing (a) Drawing of cup-shaped part: (1) before punch contacts work (2) near end of stroke. 3. Drawing (b) workpart: (1) starting blank (2) drawn part.
C) Embossing • It is used for decorative purpose or for giving details like names, trademarks, specification etc. on the sheet metal.
4. Coining (Squeezing) • This operation is used in the manufacturing of coins, medals, ornamental parts etc.
Advantages of sheet metal working • Component produced by sheet metal working are light in weight.
Advantages of sheet metal working • The component produced by sheet metal working are cheap.
Advantages of sheet metal working • The sheet metal working gives high dimensional accuracy & good surface finish.
Advantages of sheet metal working • The sheet metal working does not require skilled labour.
Advantages of sheet metal working • The rate of production is high.
Disadvantages of sheet metal working • There is limitation on the thickness of the sheet metal . • The sheet metal components have relatively low strength.
