Metal Sheet Forming Flashcards Preview

A-level Product Design > Metal Sheet Forming > Flashcards

Flashcards in Metal Sheet Forming Deck (11):
1

Bending

Bending is a metal forming process in which a force is applied to a piece of sheet metal, causing it to bend at an angle and form the desired shape.

2

Press brake machine

Bending is typically performed on a machine called a press brake, which can be manually or automatically operated. Press brakes are available in a range of sizes (commonly 20-200 tons)

3

Bending

The sheet is carefully positioned over the die and held in place by the back gauge while the punch lowers and forces the sheet to bend. The bend angle achieved is determined by the depth to which the punch forces the sheet into the die. This depth is controlled to achieve the right bend. Standard tooling is often used for the punch and die, allowing a low initial cost and suitability for low volume production. Custom tooling can be used for specialised bending operations but will add to the cost.

4

Bending costs

Standard tooling is often used for the punch and die, allowing a low initial cost and suitability for low volume production.
Custom tooling can be used for specialised bending operations but will add to the cost.

5

Bending tools

The tooling material is chosen based upon the production quantity, sheet metal material, and degree of bending. Naturally, a stronger tool is required to endure larger quantities, harder sheet metal, and severe bending operations. In order of increasing strength, some common tooling materials include hardwood, low carbon steel, tool steel, and carbide steel.

6

Spinning

Spinning, sometimes called spin forming, is a metal forming process used to form cylindrical parts by rotating a piece of sheet metal while forces are applied to one side.

7

Spinning uses

cookware, hubcaps, satellite dishes, rocket nose cones, and musical instruments.

8

Spinning tools

Spinning is typically performed on a manual or CNC lathe and requires a blank, mandrel, and roller tool. The blank is the disc-shaped piece of sheet metal that is pre-cut from sheet stock and will be formed into the part. The mandrel is a solid form of the internal shape of the part, against which the blank will be pressed.

9

Spinning process

The mandrel and blank are clamped together and secured between the headstock and tailstock of the lathe to be rotated at high speeds by the spindle. While the blank and mandrel rotate, force is applied to the sheet by a tool, causing the sheet to bend and form around the mandrel. The tool may make several passes to complete the shaping of the sheet. This tool is usually a roller wheel attached to a lever. Rollers are available in different diameters and thicknesses and are usually made from steel or brass. The rollers are inexpensive and experience little wear allowing for low volume production of parts.

10

Beaten

Beaten Metalwork is taken to mean the creation of products by hand-forming sheet, mainly non-ferrous, metals (e.g. copper, brass, gilding metal, nickel silver, silver). Similar working in ferrous metals (e.g. steel) would be more specifically referred to as a Panel Beating.

Uses hammering and non mechanical techniques to form metal sheets.

11

Press break tooling

A press brake contains an upper tool called the punch and a lower tool called the die, between which the sheet metal is located.