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3.
4.
5.
TARA Scope
7.
TARA Equipment
Manpower Qualifications
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2. Forming process
3.
4.
5.
6.
Dividing process
Joining process
Modifying Material Properties
Coating
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Forming means that the given form of solid structure is formed into another
shape without changing the weight or material composition.
Forming means bending and/or Stretching a material beyond its elastic limit to
permanently change the shape.
Forming Process are characterized as chipless or non-material removal
processes
What is the difference between Foil, Sheet & Plate?
Foil :
Sheet :
Plate :
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t 0.0059
0.0059 < t 0.25
t > 0.25
Sheet metal forming processes are those in which force is applied to a piece of
sheet metal to modify its geometry rather than remove any material. The applied
force stresses the metal beyond its yield strength, causing the material to
plastically deform, but not to fail. By doing so, the sheet can be bent or
stretched into a variety of complex shapes.
Point A
Point B
Point C
Point E
Point F
Proportional Limit
Elastic limit
Yield Point
Tensile Strength
Fracture Point
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Rolling
Forging
Extrusion
Wire, rod, and tube drawing
Cold forming, cold forging, and impact extrusion
Piercing
Squeezing processes
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Sheet metal processes can be broken down into two major classifications and one
minor classification:1. Shearing processes -- processes which apply shearing forces to cut, fracture, or
separate the material.
2. Forming processes -- processes which cause the metal to undergo desired
shape changes without failure, excessive thinning, or cracking. This includes
bending and stretching.
3. Finishing processes -- processes which are used to improve the final surface
characteristics.
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Sheet metal subjected to shear stress developed between a punch and a die is
called shearing
Shearing usually starts with formation of cracks on both the top and bottom
edges of the work piece (Point A,B,C,D). These cracks meet each other and
separation occurs
Clearance, c, between the Punch &
die typically between 2% & 10% of
Sheet Metal thickness.
As clearance increases, sheared
edges becomes rougher and zone of
deformation becomes largerclearance are smaller for softer
metals, thinner sheets.
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Punching: shearing process using a die and punch where the interior portion
of the sheared sheet is to be discarded.
Blanking: shearing process using a die and punch where the exterior portion
of the shearing operation is to be discarded.
Perforating: punching a number of holes in a sheet
Parting: shearing the sheet into two or more pieces
Notching: removing pieces from the edges
Lancing: leaving a tab without removing any material
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2.1 Bending: forming process causes the sheet metal to undergo the desired
shape change by bending without failure.
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18
Press Brake forming is a process in which a blank or work piece is placed over a
straight open die and is deformed down into a die by a punch actuated by the
Ram
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Upper Tool(Punch)
Work piece
Inside Work piece Radius (Ri)
Outside Work piece Radius(Ro)
Die Width(W)
Lower Tool Radius
Upper Tool Radius
Lower Tool
Type of bending
in Press Brake :
1. Air Bending or
3 Point
Bending
2. Bottoming or
Coining
3. Hemming
4. Folding
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Folding
Hemming
20
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Make
AVURE
AVURE
Type
Fluid Cell
Fluid Cell
Tray Size(mm)
3000x1100
3000x1200
1000
1000
50-1000
50-1000
115-230
115-245
90 Sec
105 Sec
Polyurethane bladder
Polyurethane bladder
Pad/Bladder Life(Cycles)
15000
15000
No
No
Hydraulic Medium
Castro Oil
Castro Oil
Control System
Siemems PLC
Siemems PLC
Cooling SyStems
External
External
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Tray In
Align Tray
Prefilling
Pumping
Intensifying
Holding
Decompression
Evacuation
Tray out
24
High Productivity
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What is Rolling?
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1.
2.
3.
4.
5.
6.
7.
26
1. Squaring
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2. Pre-bending
27
2.2 Stretching: forming process causes the sheet metal to undergo the
desired shape change by stretching without failure
Stretch forming is a metal forming process in which a piece of sheet metal is
stretched and bent simultaneously over a die in order to form large contoured
parts.
The basic principle of this technology is to stretch the metal beyond its yield
point in order to reach the plastic area so that the elongation is permanent.
By stretching the metal there is no compressed fibre thus much less spring back
This principle can be applied to metal sheets and profiles and in various directions
depending on the final part shape.
Force required to Stretch
F = 0,1S * (UTS+YP) / 2
S= Profile section in mm2
UTS = Ultimate tensile strength(MPa)
YP = Yield Strength (Mpa)
F = Stretching force daN
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The profile is gripped at both ends between 2 interchangeable gripping Jaws. The
material is plasticized by application of tensile stress > yield point , this first stage is
achieved by Stretching (tension) cylinders. The profile is the stretched and wrapped
around the tool, this second stage is achieved by combination of Stretching and Arm
(Wrapping) Cylinders.
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FY 14-15 : 38 SS
Process Category
Qty./SS
3 Axis-Route
2345
5 Axis-Route
26
Nibbler
297
Deburring
2722
Rubber press
999
Brake press
843
Roll forming
99
Hand forming
238
Hydraulic Press
66
Drilling
115
Chem Mill
160
Mech Mill
15
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Unique Part
Qty
Number
Sl.No
Process Category
BP Only
16
40
HP Only
16
Nibbling Only
Rolling Only
18
19
Rolling+5 Axis+VMC 3A
Routing Only
14
39
RP+BP
RP+HP
RP+Rolling
10
RP Only
34
61
11
Routing + Chamfering
12
Nibbling+Rolling
Grand Total
98
197
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Sl.No
Process Category
Unique Part
Number
Qty
1
2
3
BP Only
Rolling Only
RP Only
Grand Total
2
8
7
17
5
8
8
21
32
Process Category
Nibbling
Nibbling, BP
Nibbling, BP, CSK
Nibbling, BP, HP
Nibbling, CSK
Nibbling, HP
Nibbling, RP
Nibbling, RP, HF
Nibbling, RP,BP
Routing
Routing, BP
Routing, BP, CSK
Routing, BP, HF
Routing, BP, RP
Routing, BP, RP, Welding
Routing, HP
Routing, RP
Routing, RP, BP, HF
Routing, RP, Drilling
Routing, RP, HF
Grand Total
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Part Number
8
14
2
4
6
1
5
4
2
11
19
3
2
6
2
2
2
1
1
3
98
Total P/N 98
33
Part
Number
7
218
8
7
4
10
2
128
8
1
191
331
8
19
942
Process Category
Cutting Only
Cutting-5 Axis
Cutting-Chamfering
Cutting-Chamfering-5 Axis
Cutting-Drilling
Cutting-Drilling-Chamfering
Cutting-Drilling-Chamfering-HP
Cutting-Drilling-Chamfering-Joggeling
Cutting-Drilling-HP
Cutting-Drilling-Joggeling
Cutting-HP
Cutting-Joggeling
Cutting-Joggeling-5 Axis
Cutting-Joggleing
Query
Grand Total
Part
Number
9
97
4
3
191
86
36
12
9
33
1
1
41
1
186
710
34
Line item
M/C Name
Make
Model
Qty
Capability
Thermwood
C53
Bed Size: 5 X 10
Trumpf
TruPunch 5000
Bed Size: 5 X 10
Thermwood
M67-55DT
Thermwood
C53
Bed Size: 5 X 10
25
Cincinnati
230AS10/12
36
Davi
MAV-3-HDC AER
4027/S
40
Triform
1648-10BD
41
Avure
QFC 1X2X800
52
Cincinnati
175FM II
55
Cincinnati
No Model
59
Cyril Bath
91
IMPERIAL
35
97
Pacific
Pressformer II
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100 T press
35
F/P Insp
F/P
Deburr
H
T
To Solutionising
Rawma
Insp
To DF
36
Qualifications
Sl.No
Team Member
Name
J Govindaraj
Ramakrishna J
Bhaskarraju K
Shivanna T.C
Mallyya
Mallikarjuna K
D.Sridhar
Murali T.N
Solomon R
10
Kamalakanan G
11
12
13
Manjunath N
14
Mahendran R
15
P.Mathivanan
16
Venkatachalam
17
G.H. Appasab
18
D.Balaji
19
Ragavendra
20
J.K.Prasanna
21
Ramakrishna.V
22
Manjunath S.R
23
Manju D.P
24
C.Murali
25
26
K.Ramesh kumar
27
Manohar lal
28
Radha krishnan
29
Gribas
30
Raj kumar
31
32
Trilochan
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P1
P2
P3
P4
Rubber Press
Brake Press
Check and
Rolling
Forming
forming
Straighten
PMR #10 PMR #11 PMR #10 PMR #11 PMR #10 PMR #11 PMR #10 PMR #11 PMR #10 PMR #11 PMR #10 PMR #11 PMR #10 PMR #11 PMR #10 PMR #11
Shearing
Routing
Nibbling
Deburring
37
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