Sheet Metal Processes and Applications

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This assignment delves into various sheet metal operations, including bending, welding, extrusion, and forming. It examines the principles behind these processes, their applications in manufacturing, and the influence of factors like thickness ratio and material properties on load-bearing capacity. The document explores resources such as academic papers, industry publications, and online platforms to provide a comprehensive understanding of sheet metal fabrication.

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Table of Contents
1. Introduction.........................................................................................................................2
2. Solid works..........................................................................................................................3
2.1 Design...............................................................................................................................3
2.2 Checking the load bearing capacity............................................................................11
3. Construction......................................................................................................................14
3.1 Sheet Metal bending......................................................................................................15
3.2 Welding..........................................................................................................................17
3.3 Furnishing......................................................................................................................22
4. Final product.....................................................................................................................24
5. Conclusion.........................................................................................................................25
References.................................................................................................................................26
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1. Introduction
CPR group of company took the first step in the process of Optimization. Solid works is a 3D
CAD software that is used in designing the automation application in mechanical design. It
allows the designers to quickly draw the experiments with dimensions and features and sketch
the ideas. The designing process is coved by the SolidWorks from design to technical
communication. Solid works also include the data management in the designing process. The
productivity of our design can be increased by the SolidWorks. It is an integrated software with
intuitive design. A better cost-effective products can be delivered by this software. This 3D CAD
software allows the user to draw a solid form. It is a solid modeler and it make use of parametric
approach to create 3D solid models. In this report, design and fabrication is made for pc3 cabinet
by using a stainless steel metal. The pc3 cabinet is designed with the specified shape and
dimensions. With the space provided, the load-bearing capacity of the pc3 cabinet will be
checked.
Here, the following research questions will be answered
How can the building painting process works more efficiently using new technologies?
How can the current process enhance and works better in time management/process
optimization?
How can the current process works better in optimize a new product?
How can the environmental stress reduce the usage of new technologies?
How much the cost gets low with the new product?
The problem with this solution is to set a new product that can use for the painting process. This
can't help in innovating at CPR group of the company but it will have a new innovative product
in paint equipment trending in the market.
2. Solid works
All aspects of development product process with a seamless, sustainable design, communication,
and integrated workflow-design. The integrated software work and intuitive design interface
work together and give the focus on innovation. In solid works, building the model usually starts
with a 2D sketch (3D sketches also available). Points, arcs, lines, conics, and splines are
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available in the sketch. The drawings can be created either for assemblies or for other parts.
Views of the solid model are automatically generated (Budkin and Erofeev, 2011).
2.1 Design
To design the pc cabinet in the solid works, start a new part using inches and make enable the
sheet metal ribbon. Check next to sheet metal and right click on the ribbon. Then make the
material to 1060 alloy by right click material on browser then select 1060 alloy in the list
(Weisel, 2004).
On the top plane, a new sketch is been started
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Now draw 200mm rectangle centered on the origin is designed.
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The length and breadth is drawn (200mm)
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For Clamp space design, the measurement and the software image is shown below
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Make the thickness of the sheet metal. Use standard metal thickness. To complete select green
check.
Click the flange tool and set the dimension.
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The various dimensions of pc cabinet design is shown below
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Finally, the pc cabinet is created in solid works with CAD. The final outcome in the solid
work tool is shown in the below figure.
2.2 Checking the load bearing capacity
To obtain the stress-strain coves of the model about bending compression tests and pure
compression tests in order to performed tests on rolled steel. Steel specification are follows
(Busby, Ilevbare and Andresen, 2011): tensile 490 N/mm2<strength<610N/mm2, yield
stress>325N/mm2, and elongation>22% (Scadsoft.com, 2018) (Blackstone, 1774). Tests are
carried out under some temperatures (Scan2CAD, 2017) (Becker, 2011). Testing temperatures
are
Plate thickness: 6mm and 4.5mm
Rated temperature: 400,500,550,600 C
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Plate thickness: 9mm
Rated temperature: 200, 300, 400…, 800 C
When load increases stress also increased from 0.3%/minute to 10%/minute at 0.005 strain at
high temperature (Kao, Sung and Chen, n.d.). Calculation of pure bending compression tests
compression tests is given by the equation (Merritt, 2011).
ε =
( σ
Er )+( σ /σ k) 2
ε-Strain
σ-compression stress
E – Young’s modulus
With the experimental results, the calculation models of load curve agree (Sciencing, 2018).
.
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In pure compression test, the loading system is used. Two steel struts and an oil; cylinder are
consists in the loading system (The Constructor, 2018). For producing axial force set
horizontally produced by the oil cylinder. The inclined plates are set between the spice men and
the load cell, to maintain the loading direction as the center axis (Aguirrebeitia et al., 2018). For
the pure compression test, the first step is to produce a uniform stress distribution over the cross-
section of the spice men direction (Gupta et al., 2017). The second step is to maintain the
prescribed temperature and to heat the spice men without loading (Netfind.com, 2018)
(Volunteerbearing.com, 2018)
.
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In the below figures, pure compression tests results are shown (Informationvine.com, 2018) In
these figures, X axis shows the strain in the testing portion up to maximum stress and the Y-axis
shows at the testing portions average compressive stress (Agapov, Golovanov and Aidemirov,
2018)
.
In basics of formulation, we propose the below equation for the stress-strain curve of local
bucking (Zhu, Zhu and Mao, 2016)
.
σ ( ε0 )= σ 0 ( ε0 )
b
t
(1.2
ε 0 )+1
b- breath
t- thickness
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Using fiber model numerical analysis can be employed, from the equation 2. Under local
buckling strength of the steel structural members can be expressing. From the below figure, the
Y-axis represents stress multiplied by the width-thickness ratio and the X-axis represents the
average strain.
3. Construction
Sheet metal is simple metal which forms a very thin and flat parts. It is one of the basic forms of
metalworking and this could be used to cut and bent into various different shapes. Millions of
objects are produced using this material. The Thickness of the material differs for many
products, even though least thickness is represented as foil or leaf and the pieces thicker than
6mm are represented as the plate.
The Rolling process is the result of the material used in the manufacturing process. The stainless
steel sheets are available in various forms at standard sizes they are usually sold in the form of
flat and rectangular structure. The initial step in this process is to cut the sheet in the prescribed
shape and they are sized blank for the larger sheet.
Sheet metal processes can be divided into two major classifications and one minor classification
Shearing processes – It is the processes where the shearing forces are applied to cut,
fracture, or separate the material. Punching is a process in the shearing process using a die
and punches where the interior part of the sheared sheet is to be removed. Blanking is a
process of using a die and punches where the external part of the shearing operation is to be
removed. Perforating is the method used in punching a number of holes in a sheet. Partition
is the method where shearing the sheet into two or more pieces. While in Notching the edges
are removed Whereas in Lancing tab is left without removing any material
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Forming processes –It is the method through which the metal are formed with a specific
shape without any defect such as excessive thinning and the cracks in the metal. This method
also consists of the process of blending and stretching where the material shape can be
extended (Tomesani and Donati, 2012). Bending is the forming process which causes the
metal sheet to undergo the required shape change by bending without failure. Stretching is a
part of the forming process which causes the sheet metal to undergo the required change in
the shape by stretching without failure. Drawing in the forming process causes the sheet
metal to undergo the shape change by drawing without failure. Roll forming is a method
through which a metal strip is bent as it gone through a series of forming rolls.
Finishing processes – It is the method through which the final product can be improvised.
3.1 Sheet Metal bending
The process sheet metal bending can be done by placing the steel metal die up at the correct
place of the baggage. After placing the steel metal, the machine is going to bend the part of the
metal until it converts into a V-shape (Woodwardfab.com, 2017). This operation can be done
either manually or automatically (Weisel, 2004). The method which we call as air-bending, the
metal part is not bent in the V shape rather we left this in the air. There will be a spring option
for bending (HINO, 2012). The steel part can be drawn by using solid lines and dotted lines. The
boundaries are characterized by the solid lines and the dotted lines characterize the bending area.
The metal parts which are going to design is done by using a state-of-the-art sheet. In this design,
it will prefer the boundaries of the metal sheet (Kozłowski and Niemczynski, 2016).
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The practical images of sheet metal bending step by step process is shown below.
The sheet metal is inserted into the machine practically and the image is shown below.
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The metal is now inserted into the machine and is screwed it inside the machine for the further
processes.
The bending process of the sheet metal is provided
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The design which we are going to develop the pc cabin is parallel design system called as
Bendcad. It designs the features of the system. The parts of the steel parts are going to represent
by this design system. If we are using flat pattern system and we need to bend means, the
dimensions of that steel part will be changed and cannot be regained (Kern Lasers Systems,
2017). Our system will be useful in so many representations. The following representations are
the 1-D representation, 2-D representation, then the 3-D representation. Generally, 1-D
representation is castoff for nesting and punching process, 2-D is used for shearing and punching
process and 3-D is used for the process of bending (Elrefaey, 2015). After the three process will
complete only we will the dimension fourth (Swift and Booker, 2013) (WhatIs.com, 2017).
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The process of the planning system has developed by using the five factors. They are
Operations planner
In this feature, we are going to generate the possible ways of bending. It is going to evaluate the
cost of the manufacturing (Han and Alzamora, 2011).
Tooling System
In this system, it helps to punches the system. It is going to check the performance interference
of the tools and the parts. Each part of the tool will get bent and the complete layout will be seen
in the machine (Designs and Revisions, 2017).
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Grasping System
In this system, we can detect the grippers and where the gripper’s position will be perfectly fitted
in the machine (Gupta et al., 2017).
Motion Planner
This planner is having two types of systems. They are Fine Motion Planner and Gross Motion
Planner. The Gross Motion Planner will determine the movement of the robot and fine motion
planner will help to determine the drawing part after it gets bends (Xie and Xu, 2011).
Open Architecture Controller
The low-level machine operations are controlled by using the shelf engineering workstation. This
machine can be replaced by the bending machine controllers. This controller will give feedback
to the system (Okayasu S, 2017).
The features of the metal bending are directly and indirectly related to the geometry part. The
geometric entities which we are going to use are Hemming bend, Internal tab, Essential and
optional collinear bend, Taller flange, Shorter/longer bend, Outside/inside bend, bend graph,
Channel, Part overhang and Louver and Dimple, Corner, Large-radius bend, (Wang et al., 2014).
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The expensive computation and reasoning can be eliminated by the above features used in our
system (Xie and Xu, 2011). The goal of our system is to get output with the features consists of a
sequence of bending, which type of tool you have selected, which type of grasping workpiece
you are doing. The major problem where we are going to get is in the bending process. When we
are going to bend the first metal sheet. It is going to be very difficult and sometimes it will make
impossible to bend the sheet. At this type, we will take so many processes to come out of the
difficult (Kumar and Hussein, 2017).
3.2 Welding
Sheet metal welding
Comparing with the developed countries our country is still lagging behind using the machinery.
They will prefer manual process than the automation process. Here we are using automation
process. The automation process is used for the steel metal welding. The automatic machine is
used for the TIG welding (Hu et al., 2013).
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TIG welding
The full form of TIG welding is Tungsten inert gas welding. It is also known as Gas Tungsten
Arc Welding. It is used for the electrode which is not consumable. The construction of TIG
welding can be seen in the below figure.
The above figure shows the complete setup of the TIG welding. The TIG welding which is done
manually will be the very difficult and dangerous process. Because we will use very thin metal
sheets to weld. We have to weld the short arc length. It will be very difficult to weld manually.
There should be keen observation and very high care to be taken while doing this process. So we
are going to prefer the automation process (Chen, 2011). The welding process can be seen in the
below figure.
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The typical process of welding in the industries is shown.
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The TIG welding process is used to cut the metal sheets of thickness 1.2 and 1.5 mm. The shapes
which are used for this process is the cylindrical and conical shape. There are many advantages
in the automation TIG welding.
While doing welding of the gun operator, it will produce fumes of tungsten which affects the
health of the people. This will get reduced if we use automation process.
The welding will be done perfectly in the straight line without the shaking of the operator.
The operator will be safe without any hazards.
There is no need for the filler material. It will do welding with or without that filler.
The disturbances will be low for the TIG welding.
The Spots cannot be seen in the TIG welding.
The quality of the welding will be very high (Duflou, n.d.).
As there are some advantages definitely there will be disadvantages. The disadvantages present
in the TIG welding is
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The consumption of the electrode will be high.
The deposition of the weld will be oxidized
There will be a presence of the arc in the welding process.
After welding, there will be the presence of tiny holes (Suzuki, 2011).
Design of the component
Design of the belt
Centre distance= 3.5 × diameter of larger pulley
Length of belt= L = 2C + π (D2+D 1)
2 +(D 2D 1)2
4 C
Length of belt= L = 2C + (π(D2+D1))/2+(D2-D1)^2/4C
C- Centre distance
D1 and D2 - Diameter of pulleys
Design of pulley:
The design of the pulley can be find out by using the formula
D2
D1 + N 2
N 1
D2/D1+N2/N1
N2 and N1 - number of pulleys
Design of lead screw
The design of the lead screw can be calculated by using the formula
T= P
W = P × 60
2 πN
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T=P/W=(P×60)/2πN
T – Design of the lead screw
N – Number of turns
W-Width
Working
Before starting the operation, the TIG welding will be in the OFF position. The torch will be
attached to all sides of the mechanism. The distance between the surface of the metal sheet and
the electrode will be adjusted. This will be adjusted by using the nuts and bolts which are present
in the machine. After that, the supply will be provided to the motor and the motor starts running.
The torch which is present in the machine will cuts the metal sheet surface automatically till the
surface sheet gets to the end point (Manly, 2013). After the completion of welding in the
forward direction. The new metal sheet will place and again it will move in the reverse direction.
Like this, the process will continue to work (Bako, Abdulkadi and Babawuya, 2014). The
forward, reverse direction process and the stopping of the torch will be done by using the switch
called R/F switch. You can be seen the mechanism in the following below figure.
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We can see the difference of manual welding and automation welding in the following below
table.
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3.3 Furnishing
Steel will be used for so many decorative purposes. The steel will be highly suitable for all the
decorative purposes and to form any type of structures. The steel is preferred to use in all type of
sectors because it will look like modern and very attractive (Bako, Abdulkadi and Babawuya,
2014). It will be very hygienic and easy to clean. It will give long life. It can be recyclable. There
are some methods to make the steel in the proper manner (Swift and Booker, 2013).
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Sanding
Sanding is the very simple method. Here we are going to rub the metal surfaces aggressively to
make the surface smooth. Different type of media is used for the rubbing (Fang, 2014). The
media will be attached to the plate or the backing paper. The grains will be cut into small medias.
This small piece is called grit (Govender, Möller and Curle, 2014). The small and fine particles
will be achieved when the grit will be higher and hence we can do rubbing easily for that small
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particles.
Ultrasonic Polishing
For making the metal sheet furnishing, it will be very difficult to do manually. We won’t get into
some holes and corners. So we are going to use the ultrasonic polishing. This is a very smooth
and fine shaped tool. It will work in the frequency of 30 KHz (Bako, Abdulkadi and Babawuya,
2014). The tool is having a very small tip. This tip will not touch the surface but it will create a
pressure. With the help of the pressure, the surface will get polished. You can be seen in the
below figure.
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Sand Blasting
The sandblasting will work in the high pressure. Here we are going to use some abrasive media
for making the surface furnished. With that help of the media under high pressure, we are going
to mold the metal into the proper shape. It was having so many advantages like the strength of
the metal will be increased. The metal will be the corrosion resistance (Janarthanan, Mahendran
and Gunalan, 2015).
4. Final product
The pc cabinet is needed for remote network access from the warehouse or factory floor. The pc
cabinet is designed to any type of pc. The key locking door is maintained on the lower and upper
front doors. There are two types of key provides for pc cabinets. The changeable gland platter
with relief at the lower rear of the pc cabinet offers easy and protected cable entry (Valberg,
2010). The pretreated stainless steel is coated with the form of RAL 9005 black surfaced, a low-
gloss- polyester powder coat. There are three accessories are provided named as
1. PC Cabinet Caster Kit
2. PC Cabinet Shelf
3. PC Cabinet Rack Angle`
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The PC Cabinet Caster Kit is shown above.
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PC Cabinet Rack Angle is shown above
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The practical image of the final product is provided above.
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The pc cabinets have a self-trimming boundary flange which permits for comfortable and clean
set up into settled openings. The pc cabinets are also provided with tops for free-standing and
finished ends installations (LI, 2013). The pc cabinets could be equestrian on a worker
constructed base or the supplied with a stainless-steel-metal base (Choudhuri, 2012). The doors
cover ¼th of” thick security plate. An Entire front part of the door is formed and punched from 1
piece of 18 instrument stainless-steel. A stainless-steel sliding doors and dual pane doors are also
obtainable. Two point’s knob padlock entries are also presented (Bako, Abdulkadi and
Babawuya, 2014).
5. Conclusion
The pc3 cabin has proved in the building construction to reduce 2.5% time to the painting
process even it depends on painter speed. Overall time taken to painting process is 7.2 seconds
per square meter in which the time reduction is an 88%. This method is possible to the newly
designed product. After time reduction, the new product helps to reduce the workplace stress
since there is no release and helps to increase the overall quality of the product. Some of the
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analysis has been proven. CRP produce full-featured work. The pump is selected to handle up to
4.5 L/min therefore up to 2 products can be connected to the pump. To deliver the good results
using painting and maintenance service. The product is designed and delivered at low cost. Some
changes are made to the product. The morphological chart tool is used to solve the problem with
possible points.
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