Effect of Aluminium Alloy and Mild Steel on the Productivity in Sheet Metal Forming Processes

2012 ◽  
Vol 234 ◽  
pp. 64-68 ◽  
Author(s):  
C.N. Ashok Kumar ◽  
R. Deivanathan
Keyword(s):  
Mild Steel ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Material Handling ◽  
Operation Time ◽  
Handling Time ◽  
Machine Method ◽  
Major Factors ◽  
Selection Of

Productivity is one of the major factors that affect the profit of any industry or any product. In manufacturing industries, the productivity is showing the efficiency of the production unit. It depends on many factors such as technology, machine, method, management, materials etc. In this study, material used is considered and analyzed how it affects the productivity. Productivity is normally expressed as the number of units produced / unit time. Sheet metal forming is one of the major manufacturing processes and used for most of the products. So the selection of material is important for good quality as well as economical production. This article discusses how the material influences the productivity. For this study, a product U Clamp is considered. The materials considered for the study are the aluminum and mild steel. The U clamps are formed by aluminum as well as mild steel by using the same die. Data on operation time, material handling time are collected, analyzed and discussed.

A Study on the Effective Die Design in Sheet Metal Forming to Improve the Productivity

2014 ◽  
Vol 592-594 ◽  
pp. 806-810
Author(s):  
C.N. Ashok Kumar
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Material Handling ◽  
Operation Time ◽  
Handling Time ◽  
Die Design ◽  
Machine Method ◽  
Proper Design ◽  
Major Factors

Productivity is one of the major factors that affect the profit of any industry or any product. In manufacturing industries, the productivity is showing the efficiency of the production unit. It depends on many factors such as technology, machine, method, management etc. In this study, method of manufacturing is considered and analyzed how it affects the productivity. Productivity is normally expressed as the number of units produced / unit time. Sheet metal forming is one of the major manufacturing processes and used for most of the products. The proper design of die is important in sheet metal forming processes. This article discusses how the Combination Die can improve the productivity. For this study, a product “U Clamp” is considered. The Product requires piercing, bending and parting off operations. The Combination Die is designed and fabricated for the product and tested. Data on operation time, material handling time are collected, analyzed and discussed.

Reducing the Manufacturing Cost by Using Combination Die

2012 ◽  
Vol 234 ◽  
pp. 59-63 ◽  
Author(s):  
C.N. Ashok Kumar ◽  
R. Deivanathan
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Material Handling ◽  
Operation Time ◽  
Handling Time ◽  
Labor Cost ◽  
Manufacturing Cost ◽  
Handling Cost ◽  
Product Manufacturing

Manufacturing cost is the major factor that affects the profit of any industry or any product. Manufacturing Cost involves material, labor, equipment & tooling, quality, maintenance etc. Sheet metal forming is one of the major manufacturing processes and used for most of the products. The Die is the tooling used in the sheet metal forming. The proper design of die is important in sheet metal forming processes. This article discusses how the Combination Die can reduce the manufacturing cost, particularly the labor cost and material handling cost. For this study, a product U Clamp is considered. The Product requires piercing, bending and parting off operations. The Combination Die is designed and fabricated for the product and tested. Data on operation time, material handling time, die fabrication cost are collected, analyzed and discussed.

Hydrogeformte Strömungsprofile aus Stahlblech/Hydroforming of airfoils using bent steel sheets - Product design and technological-economical selection of sheet metal forming processes in practice

2015 ◽  
Vol 105 (10) ◽  
pp. 744-746
Author(s):  
D. Landgrebe ◽  
M. Pröhl
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Cost Effective ◽  
High Accuracy ◽  
Process Chain ◽  
Steel Sheets ◽  
Geometrical Complexity ◽  
Small Wind Turbines ◽  
Selection Of

Innerhalb des Projekts „HyBlade“ wurde ein Flügelprofil aus Stahlblech entwickelt. Zum Einsatz kommen bewährte Fertigungstechniken wie das Abkanten einer Vorform und das Hydroforming zum Kalibrieren der finalen Geometrie. Das Verfahren stellt eine hohe Maßhaltigkeit sicher – die wesentliche Voraussetzung für gute Aerodynamik und hohe Energieausbeute von Windkraftanlagen. Die wirtschaftliche Prozesskette gestattet darüber hinaus auch die Herstellung größerer Blätter mit weitaus komplexeren Geometrien.   In the HyBlade project, a sheet metal based airfoil used for blades of small wind turbines has been developed. Well known forming techniques have been used to produce a bent preform that is finally calibrated via hydrofoming. This manufacturing technology ensures a high accuracy of the blade, resulting in good aerodynamic conditions and energy efficiency. The very cost-effective process chain furthermore offers the possibility to form even larger blades with a higher geometrical complexity.

scholarly journals Influence Of Lubricants On Wear Resistance Of Aluminum Alloy Strips Series 2XXX

2015 ◽  
Vol 60 (3) ◽  
pp. 1833-1838
Author(s):  
K. Żaba ◽  
P. Kita ◽  
M. Nowosielski ◽  
M. Kwiatkowski ◽  
M. Madej
Keyword(s):  
Wear Resistance ◽  
Aluminum Alloy ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
2024 Aluminum Alloy ◽  
Aluminum Alloy 2024 ◽  
Materials Used ◽  
Oil Company ◽  
Selection Of

Abstract The article presents a properly planned and designed tests of the abrasive wear resistance 2024 aluminum alloy strips under friction conditions involving various lubricants. Test were focused on the selection of the best lubricant for use in industrial environment, especially for sheet metal forming. Three lubricants of the Orlen Oil Company and one used in the sheet metal forming industry, were selected for tests. Tests without the use of lubricant were performed for a comparison. The tester T-05 was used for testing resistance to wear. As the counter samples were used tool steel - NC6 and steel for hot working - WCL, which are typical materials used for tools for pressing. The results are presented in the form of the force friction, abrasion depth, weight loss and coefficient of friction depending on the lubricant used and the type of counter samples. The results allowed for predicting set lubricant-material for tools which can be applied to sheet metal made of aluminum alloy 2024.

scholarly journals Analysis of Material Transfer From a Soft Workpiece to a Hard Tool: Part II—Experimental Verification of the Proposed Lump Growth Model

2000 ◽  
Vol 123 (3) ◽  
pp. 474-478 ◽  
Author(s):  
M. B. de Rooij ◽  
D. J. Schipper
Keyword(s):  
Sheet Metal ◽  
Growth Model ◽  
Experimental Verification ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Material Transfer ◽  
Selection Of ◽  
Good Agreement

In this study, the lump growth model, described in an accompanying paper (de Rooij and Schipper, 2000) is validated by means of experiments performed on a deepdrawing simulator. In the experiments, the influence of material and roughness properties of both sheet and tool on the galling behavior is determined. For these experiments, a deepdrawing simulator and a selection of aluminum and zinc coated sheets with several (coated) deepdrawing tools are used. Good agreement is found between results of the lump growth model and the sheet metal forming experiments.

Data-Based Support in the Development of Press Systems Using the Example of Sheet Metal Forming

2015 ◽  
Vol 807 ◽  
pp. 130-139
Author(s):  
Julian Sinz ◽  
Daniel Hesse ◽  
Sebastian Öchsner ◽  
Peter Groche
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Manufacturing Systems ◽  
Development Process ◽  
Life Cycles ◽  
Product Complexity ◽  
Complexity Result ◽  
Market Pressure ◽  
Selection Of

The market pressure and the products of competitors are decreasing the duration of product life cycles. Besides that, special customer requirements and rising product complexity result in an increase of the effort and the costs of the development process. In order to minimize the effort of the development process as well as to handle the uncertainties which come along with the planning and selection of manufacturing systems a data-based configuration tool was developed for the use in the field of sheet metal forming. Based on the product data of existing press systems, the tool is able to predict the fundamental configuration of a newly developed press system. The utilization and functionality of the tool is illustrated on two exemplary press systems.

Punch Force Analysis in the Forming of "U" Clamps by Using Combination Die

2011 ◽  
Vol 148-149 ◽  
pp. 11-14 ◽  
Author(s):  
C.N. Ashok Kumar
Keyword(s):  
Mild Steel ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Force Analysis ◽  
Punch Force ◽  
Material Type ◽  
Aluminum Sheets ◽  
Actual Force ◽  
Key Factor

Punch force is an important factor in the sheet metal forming operations. The amount of force is mainly based on the material type, shape, size etc. The analysis on theoretical Vs actual forces is playing an important role in the optimization of the sheet metal forming processes. The total press tonnage will be based on the punch forces. Also the type of the die is a key factor in the actual force. In this study, the combination die is designed and fabricated to manufacture the U clamps. The die is used to form the U clamps by using mild steel and aluminum sheets. The punch forces are analyzed in various aspects.

ИССЛЕДОВАНИЕ ТОЧНОСТИ ДЕТАЛЕЙ, ПОЛУЧАЕМЫХ ПРИ РАЗДЕЛИТЕЛЬНЫХ ОПЕРАЦИЯХ В ПЕРЕНАЛАЖИВАЕМЫХ ШТАМПАХ

2018 ◽  
pp. 52-63
Author(s):  
Е. А. Фролов ◽  
В. В. Агарков ◽  
С. И. Кравченко ◽  
С. Г. Ясько
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Balance Method ◽  
Experiment Planning ◽  
Practical Recommendations

To determine the accuracy of the readjustable punches for separating operations (perforation + punching out) of sheet-metal forming, the accuracy parameters were analyzed using the random balance method using the method of experiment planning. Analytical dependencies are obtained to determine the values of deviation of the outer and inner contour dimensions of perforated and punched out sheet parts. From the dependencies obtained, it is possible to estimate and predict the value of deviation in the dimensions of the resulting part at any time during the operation of the punch. Practical recommendations on the calculation of the actuating dimensions of the working elements (stamping punch, matrix) of readjustable punches are offered.

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