Stamping-> Bulging (G)

Question 1

STAMPING

Answer 1

varied processes that can be applied to sheet metal manipulation

Question 2

ADVANTAGES of STAMPING

Answer 2

fast and energy efficient, preferred manufacturing method

Question 3

PUNCHING

Answer 3

sheet metal is placed over a die and then the hole is generated by a descending punch. the sheet with the hole is retained.

Question 4

a BLANK/ SLUG

Answer 4

the piece of material discarded after PUNCHING

Question 5

BLANKING

Answer 5

the same process as PUNCHING, but the SLUG/BLANK is retained and the sheet is discarded

Question 6

PLAIN or FLAT WASHERS

Answer 6

example of a product that is both PUNCHED and BLANKED.

Question 7

Why are PUNCHING and BLANKING performed sequentially when making PLAIN or FLAT WASHERS?

Answer 7

so that the waste and product streams can be kept separate.

Question 8

PERFORATING

Answer 8

when punching is performed multiple times in close proximity over a given area of sheet metal. can involve any size, shape, or combination of holes.

Question 9

NOTCHING

Answer 9

Another process for putting a hole of any shape through sheet metal, but it ALWAYS intersects the side of the sheet. often associated with bending operations.

Question 10

SEMINOTCHING

Answer 10

PUNCHING that becomes NOTCHES once the sheet is subsequently sheared.

Question 11

NIBBLING

Answer 11

process that uses subsequent notches to cut out areas of sheet metal (looks like caterpillar bites out of a leaf) mostly performed in workshops or in the field

Question 12

SLITTING

Answer 12

a process that can cut thin sheet metal without generating chips or shavings; employs ROTARY KNIVES and commonly used by can openers

Question 13

LANCING

Answer 13

a sheet metal process that combines SLITTING with LOCAL BENDING; creates sheet metal features that are out-of-plane with the surface.

Question 14

What are three examples of LANCING?

Answer 14

ANGLE LANCING (looks like an open flap)
BRIDGE LANCING (looks like a handle)
LOUVER LANCING (for ventilation)

Question 15

PIERCING

Answer 15

creates sheet metal features that are out-of-plane with the surface, uses a pointed punch, and results in a FLANGED HOLE and NO SLUG.

Question 16

EDGE BENDING

Answer 16

the sheet metal is between a PRESSURE PAD and a BASE DIE. a WIPING DIE with a rounded corner descends at a specified clearance onto the sheet metal to bend it

Question 17

BRAKE/ BENDING BRAKE/ PRESS BRAKE

Answer 17

BENDING or SHEARING can be done on this machine. the WIPING DIE with a sharp corner descends to bend the material into a v-shape

Question 18

SPRINGBACK

Answer 18

when permanently deformed, the metal will still flex back somewhat due to the elastic portion of the overall deflection as the forces are removed. the sheet metal must be OVER BENT to compensate for this.

Question 19

ROLL FORMING

Answer 19

process for bending very long lengths of sheet metal; uses a series of rollers to fold the metal strip in a series of progressive stages.

Question 20

How can you tell the difference between EXTRUDED STOCK and ROLL FORMED STOCK?

Answer 20

ROLL FORMED STOCK has a constant wall thickness everywhere and a join will be evident.

Question 21

What is one example of an application of ROLL FORMING?

Answer 21

CONTINUOUS (SEAMLESS) GUTTER for houses

Question 22

EDGE BENDS/FOLDS

Answer 22

can be added to the edges of sheet metal for the purpose of longitudinal stiffening and to hide a sharp edge

Question 23

Three main categories of EDGE BENDS/FOLDS

Answer 23

FLANGES
HEMS
BEAD or CURL

Question 24

FLANGES

Answer 24

longitudinally stiff, but not in the transverse direction.

Question 25

What is added to FLANGES to add stiffness?

Answer 25

GUSSET or DART

Question 26

BEADS and RIBS

Answer 26

stiffening options for flat areas (ribs - bed of a pickup truck)

Question 27

DEEP DRAWING

Answer 27

the primary process for making soda cans

Question 28

STRETCH FORMING

Answer 28

sheet metal is placed in tension and stretched over a properly shaped STRETCH BLOCK.

Question 29

DISADVANTAGE of STRETCH FORMING

Answer 29

leaves residual tensile stresses in the aluminum skin, which can cause cracks

Question 30

PEEN FORMING/ SHOT PEENING

Answer 30

the process that can reduce residual stresses, which keeps fatigue cracks closed.

Question 31

THIN WALLED TUBE

Answer 31

shares characteristics associated with sheet metal. it is basically sheet metal wrapped into a tube shape.

Question 32

BULGING

Answer 32

the process necessary to increase the diameter of a tube locally along its length. the THIN-WALLED TUBE is placed inside a split die with an internal cavity such that the walls are unsupported where you want the BULGE to be.

Question 33

HYDROFORMED BULGING

Answer 33

pressurized fluid is used to expand the tube and form the BULGE

Question 34

EXPLOSION FORMED BULGING

Answer 34

expanding gas is used to expand the tube and form the BULGE

Question 35

BULGE MEDIUM

Answer 35

whatever is used to push the material into BULGE shape