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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
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
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
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
Introduction to Sheetmetal
Processes
7. Fine Blanking Tools: Straight outer surfaces with negligible radius and minimum burr.
Introduction to Sheetmetal
Processes
Press Brakes
Introduction to Sheetmetal
Advantages:
Disadvantages:
Costly tool maintenance High tool down time
Introduction to Sheetmetal
Design tips.
Avoid sharp edges
Mini. Internal bend radii = 1 sheet thickness Strength & FS Standard sheet thickness Assembly constraints & Safety