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...
... middle of paper ...
...&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
However, metals can be quite hard to cut or shape into a desirable piece, requiring application of extreme forces. Depending on the project,
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
Die-forming of sheet metal has been around for thousands of years. Originally the metal was manipulated by hand and hammered into the depression, by utilizing crude grooves carved into wood or stone. This technique was used to make spouts, handles, and other forms. Since then, however; they have undergone a remarkable technological evolution. Mate-female conforming dies to create hollow forms by using hydraulic pressure or drop hammer pressure, changed die-forming forever (Paisin, 2013).
This is another property which relates the fatigue to tensile property of any material. It can be defined as the ratio of the endurance limit (Se) to the ultimate strength (Su) of the material of any structure. The value of fatigue ratio ranges from 0.25 to 0.60. It’s value solely depends upon the type of the material.
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 .
-Developed and implemented strip casting overseas to eliminate a step in the steel making process
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
Elices, M. (2004). Influence of residual stresses in the performance of cold-drawn pearlitic wires. Journal of Materials Science , 3889-3899.
Laws such as the lever law and Euler’s Buckling Theorem come into play when testing and competition begins. A structure of wood and glue surely has much more to offer than meets the eye.
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.
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 ...
In this paper we will explore on the brief manufacturing process of steel containers and some vital issues relating to the production process.
Metals possess many unique fundamental properties that make them an ideal material for use in a diverse range of applications. Many common place things know today are made from metals; bridges, utensils, vehicles of all modes of transport, contain some form of metal or metallic compound. Properties such as high tensile strength, high fracture toughness, malleability and availability are just some of the many advantages associated with metals. Metals, accompanied by their many compounds and alloys, similar properties, high and low corrosion levels, and affects, whether negative or positive, are a grand force to be reckoned with.
Mechanical engineering is a type of engineering which applies principles of physics and material science for the purpose of analyzing, designing, manufacturing and maintaining of mechanical systems (Gorp, 2005). It is involved with the production and usage of mechanical power in the operation of various machines and tools. Mechanical engineering is considered to be the most diverse engineering and has its breadth derived from the need to design tools and manufacture products which range from small individual parts to large systems. Mechanical engineering, as thought of by scholars, is related to Aerospace engineering, Manufacturing and Mechanical engineering (Van et al, 2011).
Toughness is the ability of a metal to mutilate plastically and to absorb energy in the process before it breaks or fracture. Metals can be heat treated to alter the properties of strength, ductility, toughness, hardness or resistance to corrosion. This can be done by using heat treatment processes which include precipitation strengthening, quenching, annealing and tempering. Annealing and tempering are the most prominent methods for treating metals. A material may become more or less brittle, harder or softer, or stronger or weaker, depending on the treatment used.