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Learn the techniques involved in sheet metal working, including cutting, punching, and forming operations, and explore its applications across industries. Discover the advantages and disadvantages of using sheet metal in manufacturing.
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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.
