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ME364 MET KS Ch16 - Chapter 16 Sheet-Metal Forming...

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1 Chapter 16 Sheet-Metal Forming Processes
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2 Sheet-Metal Parts (a) (b) Figure 16.1 Examples of sheet-metal parts. (a) Die-formed and cut stamped parts. (b) Parts produced by spinning.
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3 Characteristics of Sheet-Metal Forming Processes
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4 Shearing with a Punch and Die Punch fo rce , F = 0 .7 TL UTS ( 29 Punched hole Slug A blank of suitable dimension is removed from a large sheet by shearing. Major processing parameters: •The shape of punch and die, •The speed of punching, Lubrication, •The clearance c between punch and die. T : thickness of sheet, L : Total length of sheared part, UTS : material strength
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5 Shearing Figure 16.3 (a) Effect of the clearance, c , between punch and die on the deformation zone in shearing. As the clearance increases, the material tends to be pulled into the die rather than be sheared . In practice, clearances usually range between 2 and 10% of the thickness of the sheet. (b) Microhardness (HV) contours for a 6.4-mm (0.25-in.) thick AISI 1020 hot- rolled steel in the sheared region. Source: After H.P Weaver and K.J. Weinmann.
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6 Shearing Operations: Die Cutting Perforating: Punching a number of holes in a sheet, Parting: Shearing the sheet into two or more pieces, Notching: Removing pieces (or various shapes) from the edges, Lancing: Leaving a tab without removing any mateial.
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7 Die-Cutting Operations Perforating: Punching a number of holes in a sheet, Parting: Shearing the sheet into two or more pieces, Notching: Removing pieces (or various shapes) from the edges, Lancing: Leaving a tab without removing any mateial.
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8 Conventional Versus Fine-Blanking Figure 16.5 (a) Comparison of sheared edges produced by conventional (left) and by fine-blanking (right) techniques. (b) Schematic illustration of one setup for fine blanking. Source: Courtesy of Feintool U.S. Operations.
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9 Slitting with Rotary Knives Figure 16.6 Slitting with rotary knives. This process is similar to opening cans.
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10 Tailor-Welded Blanks Figure 16.7 Production of an outer side panel of a car body by laser butt- welding and stamping. Source: After M. Geiger and T. Nakagawa.
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11 Examples of Automotive Components Produced from Tailor-Welded Blanks Figure 16.8 Examples of laser butt-welded and stamped automotive-body components.
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12 The Shaving Process Figure 16.9 Schematic illustrations of the shaving process. (a) Shaving a sheared edge. (b) Shearing and shaving combined in one stroke.
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13 Shear Angles Figure 16.10 Examples of the use of shear angles on punches and dies.
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14 Compound Die (Several operations on sheet at one stroke) Progressive Die (Multiple operations on sheet with multiple strokes at the same station, while sheet is moving) Figure 16.11 Schematic illustration (a) before and (b) after blanking a common washer in a compound die. Note the separate movements of the die (for blanking) and the punch (for punching the hole in the washer).
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