manufacturing procesess created by ravinder chaudhary

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Manufacturing Processes:

Manufacturing Processes RAVINDER CHAUDHARY LECTURER IN MECHANICAL SKIET KURUKSHETRA

Introduction/ Types of Bending:

2 Introduction/ Types of Bending Two common bending methods are: V-bending Edge or wipe bending. In V-bending the sheet metal blank is bent between a V-shaped punch and die. The figure below shows a front view and isometric view of a V-bending setup with the arrows indicating the direction of the applied force: Figure courtesy of Engineering Research Center for Net Shape Manufacturing

Introduction/ Types of Bending:

3 Introduction/ Types of Bending Edge or wipe bending (conducted in lab) involves cantilever loading of the material. A pressure pad is used to apply a Force to hold the blank against the die, while the punch forces the workpiece to yield and bend over the edge of the die. The figure below clearly illustrates the edge (wipe)-bending setup with the arrows indicating the direction of the applied force (on the punch) : Figure courtesy of Engineering Research Center for Net Shape Manufacturing

Bending Animation:

4 Bending Animation

Bending Animation:

Bending Animation 6

Springback Animation:

Springback Animation 7

Springback Animation:

Springback Animation 8 Springback

Introduction/ Shearing:

Introduction/ Shearing The Shearing process involves cutting sheet metal into individual pieces by subjecting it to shear stresses in the thickness direction, typically using a punch and die, similar to the action of a paper punch. Unlike cup drawing where the clearance between the punch and the die is about 10% larger than the sheet thickness, the clearance in conventional shearing is from 4 to 8% of the sheet thickness. 10

PowerPoint Presentation:

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 18.3 Basic sheet metalworking operations: (c) shearing Shearing of Sheet Metal

PowerPoint Presentation:

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 18.2 Basic bulk deformation processes: (a) rolling Rolling

PowerPoint Presentation:

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 18.2 Basic bulk deformation processes: (b) forging Forging

PowerPoint Presentation:

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 18.2 Basic bulk deformation processes: (c) extrusion Extrusion

Topics:

Topics Introduction The Extrusion Process Extrusion Practice Hot Extrusion Direct extrusion Indirect extrusion Extrusion Defects Extrusion Equipment The Drawing Process Drawing Practice Defects and Residual Stresses Drawing Equipment

Introduction:

Introduction Extrusion – It is a process where a billet is forced through a die. Parts have constant cross-section Typical Products of Extrusion – Sliding Doors, tubing having various cross-sections, structural and architectural shapes and door and window frames. Drawing – It is a process where a cross-section of solid rod, wire, or tubing is reduced or changed in shape by pulling it through a die.

Extrusions:

Extrusions Fig : Extrusions and examples of products made by sectioning off extrusions.

The Extrusion Process:

The Extrusion Process Types of Extrusion : Direct Extrusion (or) Forward Extrusion – Billet is placed in a chamber and forced through a die opening by a hydraulically-driven ram or pressing stem. Indirect Extrusion – Die moves towards the billet.

Direct Extrusion:

Direct Extrusion Fig : Schematic illustration of direct extrusion process.

Types of Extrusion:

Types of Extrusion Fig : Types of Extrusion (a) indirect (b) hydrostatic (c) lateral

Hot Extrusion:

Hot Extrusion Extrusion is carried out at elevated temperatures – for metals and alloys that do not have sufficient ductility at room temperature, or in order to reduce the forces required.

Drawing Process:

Drawing Process In this process the cross section of a round rod or wire is typically reduced or changed by pulling it through a die Die angle has great influence on the drawing force and the quality of the drawn product Fig : Process variables in wire drawing. The die angle, the reduction in cross-sectional area per pass, the speed of drawing, the temperature, and the lubrication all affect the drawing force, F.

PowerPoint Presentation:

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 18.2 Basic bulk deformation processes: (d) drawing Wire and Bar Drawing

Sheet Metalworking:

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Sheet Metalworking Forming and related operations performed on metal sheets, strips, and coils High surface area‑to‑volume ratio of starting metal, which distinguishes these from bulk deformation Often called pressworking because presses perform these operations Parts are called stampings Usual tooling: punch and die

PowerPoint Presentation:

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 18.3 Basic sheet metalworking operations: (a) bending Sheet Metal Bending

PowerPoint Presentation:

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e Figure 18.3 Basic sheet metalworking operations: (b) drawing Deep Drawing

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