Introduction to Sheetmetal

HTMT - EDS

Introduction to Sheetmetal

Introduction:
For complicated shapes easy to reshape & secondary operation Easy & Mass production Different grade materials

Cheaper cost
Repeatability & Interchangeability
HTMT - EDS 2

Introduction to Sheetmetal

Design Points to be considered:

Design indent & Functionality Rigidity - Strength Burr side Grain direction

Heat treatment
Surface finishing & coatings
HTMT - EDS 3

Introduction to Sheetmetal

Sheetmetal Processes:
Blanking Piercing Bending Coining Lancing Louvering

Drawing

Collar drawing

HTMT - EDS

Introduction to Sheetmetal

Terminology:
Strip layout Pitch Flatness Grain direction

Burr side
Radius side Burnished band

Bend allowance
Development Length

Minimum bend radii

HTMT - EDS

Introduction to Sheetmetal

Blank

Radius

Burr

Break

Burnished band
* Blank generally takes Die profile dimension
HTMT - EDS 6

Introduction to Sheetmetal

Piercing
Radius

Burnished band

Break

Burr

** Pierced hole generally takes Punch profiles dimension

HTMT - EDS 7

Introduction to Sheetmetal

Production Process:
1. Press tools:
Single stage Multiple stage

2. Press Brakes
3. CNC Presses

Progressive tools
Compound tools Combination tools Drawing dies Fine blanking dies
HTMT - EDS 8

Introduction to Sheetmetal

Processes
1. Single Stage Tool: Only one operation eg Blanking or piercing

2. Multi-Stage Tool:
Component needs more than one operation eg Blanking, piercing, bending etc. done in separate tools, stagewise.
HTMT - EDS 9

Introduction to Sheetmetal

Processes
3. Progressive Tools:
Component needs more than one operation

e.g. Blanking, piercing, bending etc. done in same tool, as stage wise. Stock is fed into tool via pneumatic feeders. Plain strip converted to Product at the end of the stroke Complex die design, but suitable for mass production.
HTMT - EDS 10

Introduction to Sheetmetal

Processes
4. Compound Tools:
Component needs more than one operation

Single stage; Blanking & piercing done simultaneously Dimensional accuracy, and Flat components Complex design; More Die Cost; Suitable for mass production.
HTMT - EDS 11

Introduction to Sheetmetal

Processes
5. Combination Tools:
Component needs more than one operation

Multi stage tools; similar to progressive tools Blanking, piercing, forming operations carried out in stage wise. 6. Drawing Dies: Shallow drawing - One step draw process

Deep drawing - More than one drawing.

HTMT - EDS 12

Introduction to Sheetmetal

Processes
7. Fine Blanking Tools: Straight outer surfaces with negligible radius and minimum burr.

This is achieved through V shape pressure pads and counter punch.

Similar to Compound dies

Triple action press is needed

Suitable upto 12 mm sheet thickness.
HTMT - EDS 13

Introduction to Sheetmetal

Processes
Press Brakes

For forming operation

Bend angles can be varied easily.

CNC Presses: standard punches & tools

HTMT - EDS 14

Introduction to Sheetmetal

Advantages:

Accurate & precision components

Only possible in Sheetmetal (e.g. switch gear components) Mass production.

Intricate & complicated shapes can be achieved

Disadvantages:
Costly tool maintenance High tool down time

Needs skilled operators for die setting & maintenance.

HTMT - EDS 15

Introduction to Sheetmetal

Design tips.
Avoid sharp edges
Mini. Internal bend radii = 1 sheet thickness Strength & FS Standard sheet thickness Assembly constraints & Safety

Keep in mind, Closer the tolerance, Higher the cost

HTMT - EDS 16