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Introduction to Sheetmetal
HTMT - EDS 1
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Introduction to Sheetmetal
HTMT - EDS 2
Introduction:
•For complicated shapes
•easy to reshape & secondary operation
•Easy & Mass production
•Different grade materials
•Cheaper cost
•Repeatability & Interchangeability
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Introduction to Sheetmetal
HTMT - EDS 3
Design Points to be considered:
•Design indent & Functionality
•Rigidity - Strength
•Burr side
•Grain direction
•Heat treatment
•Surface finishing & coatings
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Introduction to Sheetmetal
HTMT - EDS 5
Terminology:
• Strip layout
• Pitch
• Burr side
• Radius side
• Burnished band
• Minimum bend radii
• Flatness
• Grain direction
• Bend allowance
•Development Length
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Introduction to Sheetmetal
HTMT - EDS 6
Break
RadiusBlank
Burnished band
* Blank generally takes Die profile dimension
Burr
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Introduction to Sheetmetal
HTMT - EDS 7
Break
Radius
Piercing
Burnished band
** Pierced hole generally takes Punch profile’s dimension
Burr
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Introduction to Sheetmetal
HTMT - EDS 8
Production Process:
1. Press tools:
• Single stage
• Multiple stage
• Progressive tools
• Compound tools
• Combination tools
• Drawing dies
• Fine blanking dies
2. Press Brakes
3. CNC Presses
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Introduction to Sheetmetal
HTMT - EDS 9
1. Single Stage Tool:
• Only one operation•eg Blanking or piercing
2. Multi-Stage Tool:
•Component needs more than one operation
•eg Blanking, piercing, bending etc. done in
separate tools, stagewise.
Processes
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Introduction to Sheetmetal
HTMT - EDS 10
3. Progressive Tools:
• Component needs more than one operation
• e.g. Blanking, piercing, bending etc. done in same
tool, as stage wise.
• Stock is fed into tool via pneumatic feeders.
• Plain strip converted to Product at the end of the
stroke
• Complex die design, but suitable for mass
production.
Processes
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Introduction to Sheetmetal
HTMT - EDS 11
4. Compound Tools:
• Component needs more than one operation
• Single stage;
• Blanking & piercing done simultaneously
• Dimensional accuracy, and Flat components
• Complex design; More Die Cost;
• Suitable for mass production.
Processes
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Introduction to Sheetmetal
HTMT - EDS 12
5. Combination Tools:
• Component needs more than one operation
• Multi stage tools; similar to progressive tools
• Blanking, piercing, forming operations carried out
in stage wise.
Processes
6. Drawing Dies:
• Shallow drawing - One step draw process
• Deep drawing - More than one drawing.
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Introduction to Sheetmetal
HTMT - EDS 13
7. Fine Blanking Tools:
• Straight outer surfaces with negligible radius and
minimum burr.
• This is achieved through ‘V’ shape pressure pads
and counter punch.
• Similar to Compound dies
• Triple action press is needed
• Suitable upto 12 mm sheet thickness.
Processes
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Introduction to Sheetmetal
HTMT - EDS 14
Press Brakes
• For forming operation
• Bend angles can be varied easily.
CNC Presses:
• standard punches & tools
Processes
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Introduction to Sheetmetal
HTMT - EDS 15
Advantages:• Accurate & precision components
• Only possible in Sheetmetal (e.g. switch gear components)
• Mass production.
•Intricate & complicated shapes can be achieved
Disadvantages:
• Costly tool maintenance
• High tool down time
• Needs skilled operators for die setting & maintenance.
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Introduction to Sheetmetal
HTMT - EDS 16
Design tips….
Avoid sharp edges
Mini. Internal bend radii = 1 sheet thickness
Strength & FS
Standard sheet thickness
Assembly constraints & Safety
Keep in mind, Closer the tolerance, Higher the cost