Introduction:
Sheet Metal Forming is a process of making a flat sheet metal into a desired shape part without excessive localized thinning or Fracture.
This following report on sheet metal forming consists of forming study of two components one given in the course and an another outside of our field of work, it details the materials used and their metallurgical properties and alternative materials that can be considered. Detail the forming process used and an alternative route. Also Detail the forming effects such as spring back and the methods to reduce them.
Mechanical properties of metals:
Formability is the ease with which the sheet metal can be shaped through plastic deformation
Parts, when in service and while forming, are subjected to forces. It is necessary to know the characteristics of the material to design and form the component so that any resulting deformation will not result in failure of the component in service and while forming.
These characteristics of material can be determined by stress strain tests using a test sample, one of the most common is tensile test, which measures two types of mechanical properties 1.Strength properties: yield strength, Modulus of elasticity, Ultimate tensile strength. 2. Ductile properties: percentage of elongation
Deformation of a material or strains depends on the magnitude of stress. For most metals that are stressed in tension stress and strain are proportional Deformation at which stress is proportional to stain is called elastic deformation, a plot of stress versus strain results in a linear relationship. The slope of this linear segment represents to the modulus of elasticity E. This modulus indicates the stiffness of the material or material’s resistance to el...
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...&sons, Inc. seventh edition 2007.
[4]http://www.ndt-ed.org/EducationResources/CommunityCollege/Materials/Mechanical/Tensile.htm
[5]http://www.alueurope.eu/pdf/Aluminium_in_cars_Sept2008.pdf
[6]Sheet Metal Forming Processes and Die Design
By VukotaBoljanovic
[7] Materials for Automobile Bodies, Second Edition by Geoff Davies
[8] The automotive body manufacturing systems and processes
Mohammad A. Omar
[9] Metal Forming Handbook /Schuler (c) Springer-Verlag Berlin Heidelberg 1998
[10] The role of natural aging on subsequent precipitation during the artificial aging of AA6111 aluminium alloy
S.Esmaeili, D.J.Lloyd and W.J Poole
[11] Handbook of Fabrication Processes, By Orville D. Lascoe
[12] Progressive Dies: Principles and Practices of Design and Construction
Society of Manufacturing engineers, Edited by Donald A. Peterson
Elastic strain region at small and big end of connecting rod is shown in figure no. 10. The maximum and minimum equivalent strain values are 0.00033975 and 2.1407e-10 respectively. Due to applied pressure there will be change in original dimensions of the connecting rod and hence strain developed can be
The continuous slab casting is started by adding and mixture the basic raw materials such as steels, silicon, magnesium and other basic materials of steelmaking in the furnace. The steel has low carbon contained, which is below 2% of carbon in the steel. The process of continuous slab casting process begins with melting and mixing the raw materials in the furnace. The molten steel in the ladle is tapped out from the bottom of the ladle into the intermediate container called as tundish by gravitational force, which helps the filling the mold along the continuous steel casting. Additionally, the continuous slab casting process is required a large space for the casting operation due to the tundish alone is located approximately 250m above the ground level and it can hold several tones of steel. The roles of the tundish are to supply a certain constant amount of the ...
Continuum Mechanics is the branch of mechanics which deals with the study of deformation and motion of continuous bodies. Primarily, a continuous solid body can be categorized into two types: (i) Rigid body and (ii) Elastic body. When external forces are applied on the body and the relative positions of its particles do not change at all, the body is said to be perfectly rigid body, otherwise it is said to be elastic body. A body is called strained, if under the influence of some external forces, the relative positions of its particles get altered. The change in the relative position of particles is called deformation. In practice, all solid bodies undergo deformation up to some extent by the application of suitable forces upon them. There are certain bodies which regain their original configuration when the deforming forces are removed. For example, the wire regains its original length after
Equation 3.3 is utilized for the assessment of the structural torsional stiffness of the handle for its design and analysis. This equation is inputted into the spreadsheet and plotted to look for the coefficient. The coefficient is the structural torsional stiffness, KT of the handle. All values needed for the equation are measured from the handle model in SolidWorks.
Strain hardening is the additional stress required to cause slip in a material. It occurs when dislocations in a crystal interact with each other or when the dislocations observe hindrance in their motion. Either dislocations pile up at the barriers of slip plane of crystal or they intersect other dislocations. The latter can result in jogs which restrict its motion. Jogs readily occur in the cases of screw dislocations which cases to restrict the dislocation movement thus increasing strain hardening but not so in case pf edge dislocation. The strain hardening or work hardening behavior for FCC, BCC and HCP can be observed by taking the case of Iron, copper and magnesium where iron is BCC, copper is
In order to determine the stress points in a plastic object, we used a photoelastic effect where we looked at the object through a polarizer. When the plastic was squeezed together, changes in the color occurred, displaying points with greater stress.
Metal stamping machines are utilized to give the careful shape and parameters to the metal items. At the point when a metal sheet is embedded into the metal stamping machine, it can be formed into the definite shape. The sort of shape that must be given to the item ought to be pre-decided before putting the metal in the stamping machines. The client gives an example or a chart of the item that must be made. Now and again, the client may not realize what the last item will resemble. He will accompany an unclear thought of what reason the item would serve. Most metal stamping makers have outlining abilities to help the client with what the real plan and necessities of the item ought to be.
This Introduction is talking about the aluminium alloys by dispersion strengthening and precipitation hardening. Firstly, is the dispersion strengthening to introduce. The dispersion strengthening is the some of metal alloys of hardness may be raise by some very small and even dispersed particles in the origin phase matrix. Whether inside the powder compaction contain of some insoluble particles ,this call dispersion strengthening. The other phases of the particle are normally the most strong strengthening agent .This phase of particle is practically very high strength in the engineering materials. This phase of particle can controls properties of the alloy by the shape, size and amount. This phase is call the second phase.
Aluminum is a lightweight, silvery metal. The atomic weight of aluminum is 26.9815; the element melts at 660° C (1220° F), boils at 2467° C (4473° F), and has a specific gravity of 2.7. Aluminum is a strongly electropositive metal and extremely reactive. In contact with air, aluminum rapidly becomes covered with a tough, transparent layer of aluminum oxide that resists further corrosive action. For this reason, materials made of aluminum do not tarnish or rust. The metal reduces many other metallic compounds to their base metals. For example, when thermite (a mixture of powdered iron oxide and aluminum) is heated, the aluminum rapidly removes the oxygen from the iron; the heat of the reaction is sufficient to melt the iron. This phenomenon is used in the thermite process for welding iron .
I’m doing investigation on defect and failure in the aircraft structures which is important for the prevention of further catastrophic incidents. One of the main reason for the failure of the aircraft components or structure under high stress which is during the operation where the component no longer bear the stress which is imposed.
Aluminum is one of a number of soft metals that scientists call "poor" metals. It can be shaped and twisted into any form. It can be rolled into thick plates for armored tanks or into thin foil for chewing gum wrappers. It may be drawn into a wire or made into cans. Aluminum is a generally popular metal because it does not rust and it resists wear from weather and chemicals. (Bowman, 391) Aluminum is an element. Its atomic number is thirteen and its atomic weight is usually twenty-seven. Pure aluminum melts at 660.2ºC and boils at 2500ºC. Its density is 2.7 grams per cube centimeter. Aluminum is never found uncombined in nature. (Bowman, 391) Aluminum is a very useful metal that is light, easy to shape and can be strong. This makes aluminum one of the most used metals in the world, right behind iron and steel. (Geary, 185) In its pure state, aluminum is quite weak compared to the other metals. However, its strength can be greatly increased by adding small amounts of alloying elements, heat-treating, or cold working. Only a small percentage of aluminum is used in its pure form. It is made into such items as electrical conductors, jewelry, and decorative trim for alliances and cars. A combination of the three techniques has produced aluminum alloys that, pound for pound, are stronger than structural steel. Some common metals used in alloys for aluminum are copper, magnesium and zinc.(Walker, 31) The added elements give the aluminum strength and other properties. (Newmark, 41) Aluminum is one of the lightest metals. It weighs about 168.5 pounds per cubic foot, about a third as much as steel which weighs 487 pounds per cubic foot. (Neely, 214) As a result, aluminum has replaced steel for many uses. For example, some ...
Concrete has been cast in rigid formwork since it was invented. The traditional rigid formworks are constructed using flat, straight sheets with uniform section built with 90-degree joints [1]. The resulting forms are simple, uniform cross-section shapes. However, uniform section or prismatic shapes are not always the most desirable. Unlike the rigid formwork, fabric formworks
Metallurgy is the field of materials science and material engineering that studies the physical and chemical behaviour of metallic elements, their microstructure compounds and their mixtures, which are mostly known as alloy. Metallurgy can be refers as the technology of metals where science is applied to the production of metals, and the engineering of metal components for the uses of products for consumers and manufacturers.
Some steel containers are made through deforming the steel by means of extruding, forging, spin forming, ...
It states that, the amount by which a material body is deformed is linearly related to the force causing the deformation i.e. stress. Or more clearly stress is directly proportional to the deformation. Those solid obey Hook’s l...