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    Metal Forming Lab - Experiment No 5 - Sheet Metal Forming

    Uploaded by

    Subhasis Biswal
    The document provides instructions for fabricating a sheet metal funnel through a series of forming operations. It first describes sheet metal forming processes like shearing, bending, and deep drawing. It then gives step-by-step instructions for making different self-secured sheet metal joints, including internal grooved, double grooved, and knocked-up joints. Finally, it includes diagrams showing the dimensions for the funnel to be fabricated, with detailed procedures for marking and cutting out the shape from sheet metal. The goal is to have students practice common sheet metal forming techniques to produce a useful part.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Metal Forming Lab - Experiment No 5 - Sheet Metal Forming

    Uploaded by

    Subhasis Biswal
    1K views4 pages
    The document provides instructions for fabricating a sheet metal funnel through a series of forming operations. It first describes sheet metal forming processes like shearing, bending, and deep drawing. It then gives step-by-step instructions for making different self-secured sheet metal joints, including internal grooved, double grooved, and knocked-up joints. Finally, it includes diagrams showing the dimensions for the funnel to be fabricated, with detailed procedures for marking and cutting out the shape from sheet metal. The goal is to have students practice common sheet metal forming techniques to produce a useful part.

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    Metal Forming Lab - Experiment no 5- Sheet Metal forming

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    The document provides instructions for fabricating a sheet metal funnel through a series of forming operations. It first describes sheet metal forming processes like shearing, bending, and deep drawing. It then gives step-by-step instructions for making different self-secured sheet metal joints, including internal grooved, double grooved, and knocked-up joints. Finally, it includes diagrams showing the dimensions for the funnel to be fabricated, with detailed procedures for marking and cutting out the shape from sheet metal. The goal is to have students practice common sheet metal forming techniques to produce a useful part.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    1K views4 pages

    Metal Forming Lab - Experiment No 5 - Sheet Metal Forming

    Uploaded by

    Subhasis Biswal
    The document provides instructions for fabricating a sheet metal funnel through a series of forming operations. It first describes sheet metal forming processes like shearing, bending, and deep drawing. It then gives step-by-step instructions for making different self-secured sheet metal joints, including internal grooved, double grooved, and knocked-up joints. Finally, it includes diagrams showing the dimensions for the funnel to be fabricated, with detailed procedures for marking and cutting out the shape from sheet metal. The goal is to have students practice common sheet metal forming techniques to produce a useful part.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 4

    INTRODUCATION TO METAL FORMING

    SHEET METAL FORMING


    Many products are manufactured from sheet metal involving combination of processes such as shearing,
    bending, deep drawing, spinning etc. These processes are characterized by localized deformation and

    bulk shape change of the parts, but lead to configurational changes. Sheets have high surface area to
    volume ratio of starting metal which distinguishes these from bulk deformation. Sheet metal forming is
    es are required to perform these operations. Parts are usually called
    stampings and usual tools involve punches and dies. Sheet metal operations can involve combination of
    stresses, eg.
    Stretching of the metal (tensile stresses)
    Bending of the metal (tensile and compressive stresses)
    Cutting of the metal (shear stresses)

    Fig. 6: Schematic of some sheet metal working operations (top) shearing (bottom) bending.

    16
    (a)

    (b)

    (c)

    Fig. 7: Some of the apparatus available in engineering metallurgy lab to perform sheet metal forming
    (a) Shearing equipment (b) Bending equipment (c) Folding equipment.

    17
    EXERCISE-2
    SHEET METAL FORMING
    Objective

    (i) To prepare a sheet metal product (Funnel).


    (ii) Report the various parameters for the various passes during the rolling of the given metal piece.

    Equipment & material


    Mallet, Hand Snip, Bench Vice, Grooving Tool, Scriber, Scale, Marker, Light Weight Hammer, Divider
    and Metal Sheet

    Demonstration
    Self secured sheet metal joints

    (a) Internal grooved joint


    Mark out portions of given sheets near edges to be joined with a marker.
    Fold the sheets at edges in the portion marked, first at right angles to the plane of the sheet
    and then at 180 to the plane.
    Insert one folded sheet into the other.
    Groove the seam using grooving die.

    (b) Double grooved joint


    Fold sheets after making them as per the instructions given.
    Cut a piece of sheet (called strap) of required width.
    Strap width = (4x size of marked edges) + (4 x thickness of sheet).
    Close the edges of the strap slightly.
    Slip the strap on the bent edges of the sheets after bringing them.

    (c) Knocked-up joint


    Fold one sheet and close edges slightly.
    Bend one sheet to form a right angles band.
    Slip the second sheet in the folded one.
    Close the right angled sheet using a mallet.

    18
    Fig. 8: Approximate dimensions of the funnel to be fabricated.

    Procedure for funnel:


    Draw the elevation on full scale
    Complete the cone by extending the lines A and G
    Choose a point Z and draw curves with Z as a center, and ZA and ZX as radius
    Draw the vertical line Z3, meeting the internal curve at D, and external curve at 3
    Starting from D mark lengths DC, CB, BA, DE, EF and FG, each equal to nd/6.
    Again starting from 3 mark length 3-2, 2-1, 1-0, 3-4, 4-5 and 5- . (D and d
    are major and minor diameters)
    Draw another curve with Z as a center and ZX+5 mm as radius.
    Joint AO and G6 and extend it to cut the outer curve at points H and I, respectively.
    Provide a margin of 5 mm on one side, and 10 mm on another side for joint.
    Cut out the required portion and form the conical portion.
    Make the bottom half of the funnel.

    Fig. 9: Final form of funnel to be fabricated in the lab.

    19

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