Edge Bending Processes ‘Sheet metal of different sizes can be bent an innumerable amount of ways, at different locations. (0 achieve desired part geometries, One of the most important considerations int sheet metal manufacture is the condition of the sheet metal’s edges, particularly with regard to the part after manufactuse. Edge bending operations are commonly used in industrial sheet metal processing and involve beading a section of the metal that is small selative to the part ‘These sections are located at the edges. Edge bending ss used to elsmnate sharp edges. to provide geometric surfaces for purposes sich as joining. to protect the part, to increase Stiffiiess and for coumetic appearauice. Flanging is a process that bends an edge. usually to a 90 degres angle Figure: FLANGING SHEET- METAL. SIDE VIEW Sometimes the sheet metal’s material is pumasely subjected to tensions or compressions. in the procasses of stretch flanaing and shrmk flanging respecuvely. In addition t bending the edge. these operations also give it s curve Figui 74 DIFFERENT TYPES OF FLANGES STRAIGHT STRETCH SHRINK FLANGE FLANGE FLANGE TOP VIEW Beeding ie cummou iia the edlge trontncnt Of dheut metal parte and cen alse be weed to fom the worling structure of parts. stich as hinges. Beading forms q curl over a parts edse This bead can be formed over a strught of curved axis. There are many dafferent teckuscues £52 Forming 9 bead. Some methods form the bead progressively. with muluple stazes. Usine several different die awremgemtedts! Ofer shedt mactal bending processes produces tend wil Single dic In a process called wirang. the mactal’s edge is bent over a wire. How the bead i Fees Sal lero ces ieee le Secs as Ge tige heeleociaemoe eaeerege nc Seen Figure:275 BEADING WITH A SINGLE DIEBrADIING Witt A SINGLE vir peaD Hemming is an edge bending process in which the edge of the sheet is bent completely over on ireclt Figure:276 HEMMING OF SHEET METAL FLAT HEM OPEN HEM Se ce pelle tng re erect ete rel Sar eStore rece e Blosticaliv deformed into position. Ar the bend= are locked tozerher. cach bend helps resist the deformation of the other bend. prowiding a well fortified jowt structure. Double seassinz has Leen emploved to create Watertight of airtight jounts between sheet metal parts, Figure:277 SEAMING OF SHEET METAL 15.1 INTRODUCTION Process planning involves the sequence of indi- ‘vidual manufacturing operations needed to produce a given component or part. The sequence of opera- tions are recorded on a route sheet. The route sheet is the listing of production operations and associ- ated machine tools for a product or assembly. ‘The three functions of process planning are: (a) planning the process, (b) determining the cutting ‘conditions and (¢) time standards for the operation. ‘Traditionally, the above functions were carried out with very high manual and clerical content. Many routine tasks involved similar design and activi- ties. Now-a-days, these kind of decisions are made with the help of computers. This process is known, as computer-aided process planning (CAPP). 15.2 TRADITIONAL PROCESS PLANNING In traditional process planning, much variations in the level of detail was found among different com- panies and industries. variability among planners resulted in difficulties in the conventional process planning procedures. New machine tools in the fac- tory rendered old routings less optimal. Machine 15.3 AUTOMATED PROCESS PLANNING Due to the large amount of problems faced with ‘manual process planning, attempts have been made in the recent years to computerise the logic, judg- ment and experience into computer programs. Based on the characteristics of a given part, the computer automatically generates the manufactur ing operation sequence. A computer-aided process planning (CAPP) system reduces considerably the clerical work as well as the work of the manufac turing engineer. It also generates rational, consist- ent and optimal production routings. 15.4 BENEFIT OF CAPP Computer-aided process planning has the follow- ing advantages: @ Product rationalisation and standardi- sation: CAPP leads to more consistent and logical process plans than manual planning. It results in lower manufacturing cost and higher product quality. Increase in productivity of process planners: Standard process plans in the data file mduces the planning time and hence GTory rendered old routings icss optimal. Machine breakdowns forced shop personnel for temporary routings. Hence, this process is very time consum- ing and lesser satisfactory. 262 (iD) Reduced Lead Time: Lead time by CAPP reduces considerably as compared to manual Process planning. Gv) Incorporation of other application Program (y) Improved legibility than manual programs The following two types of CAPP systems are used \n Process Planning: (i) Retrieval-type CAPP system (also called variant system) Gi) Generative CAPP system ) Generative CAPP system 5.5.1 Retsieval-type Process Planning System etrieval-type process planning is also known as ariant system. This system uses part classifica- on and coding and group technology as founda- on. In this system, parts produced in a plant are rouped into part families and are distinguished seording to their manufacturing characteristics. or each part family, a standard process plan is es- ‘blished. This process plan is stored in computer es. When new workpieces that belong to similar arts are to be manufactured, the standard process lan is retrieved. It facilitates quick process plan- ing. The machine routing may be the same for \e new part, but the specific operations on each tachine may be different. The complete process lan must document the operations ax well ax the squence of machines through which the workpart routed. 5.5.2 Generative Process Planning System lenerative Process planning system represents an lternative approach to automated process lanning. It involves the use of computer to create 1 individual process plan from scratch. The planners: Standard process plans in the data file reduces the planning time and hence increases the productivity. One system reported 60% increase in productivity. Manufacturing Processes It process is created automatically and without human assistance. The computer employs a set of algorithms to progress through the various technical and logical decisions towards the final plan of manufacturing. Inputs to the system include a comprehensive description of the workpicee. It may be in the form of part code number to summarize the workpiece data. This Process synthesises the design of the optimum Process sequence. It is based on. the analysis of Part geometry, material and other workpiece- related factors. An ideal generative process planning package must be capable of creating an optimal plan. How- ever, current generative-type systems are far from ‘ever, current generative-type systems are far from practicability. This system is suitable for only a limited range of manufacturing processes. 15.6 STRUCTURE OF CAPP SYSTEM Figure 15.1 shows the procedure used or the structure of a retrieval process planning system. ‘The computer-aided process planner initiates the procedure by entering the part code number at a ‘computer terminal. The CAPP program then searches the part family matrix file to determine ‘whether the matching parameters exist. If a file with the identical code number exists with standard machine routing and operation sequence, the respective computer files are diaplayed to the user. ‘The user examines the exhibited standard process plan and ensures its compatibility with the new part design. After editing, the user prepares the document on the paper in the required form. If an exact match does not exist in the compu- ter, the user may search the machine routing file and the operation sequence file for similar parts, to develop a plan for the new part. Once the proc- ess plan for a new part code number is entered, it becomes the standard process for future parts and is stored for further use.