A novel process for transforming sheet metal blanks: Ridged die forming

Up to 20% of all sheet metal produced is scrapped as blanking skeletons. A novel process is therefore designed and examined, aiming to transform tessellating 'pre-blanks' in-plane into the real blanks required for stamping. Prior to blanking, the sheet is formed with a set of ridged dies, from which pre-blanks are cut and then flattened into true blanks. Several different approaches to designing ridged dies are evaluated by simulation and experiment, and the best results demonstrate a potential reduction in blanking yield losses for can-making from 9.3% to 6.9%. © 2013 CIRP.

Mode I fracture of sheet metal

The perceived wisdom about thin sheet fracture is that (i) the crack propagates under mixed mode I & III giving rise to a slant through-thickness fracture profile and (ii) the fracture toughness remains constant at low thickness and eventually decreases with increasing thickness. In the present study, fracture tests performed on thin DENT plates of various thicknesses made of stainless steel, mild steel, 6082-O and NS4 aluminium alloys, brass, bronze, lead, and zinc systematically exhibit (i) mode I “bath-tub”, i.e. “cup & cup”, fracture profiles with limited shear lips and significant localized necking (more than 50% thickness reduction), (ii) a fracture toughness that linearly increases with increasing thickness (in the range of 0.5–5 mm). The different contributions to the work expended during fracture of these materials are separated based on dimensional considerations. The paper emphasises the two parts of the work spent in the fracture process zone: the necking work and the “fracture” work. Experiments show that, as expected, the work of necking per unit area linearly increases with thickness. For a typical thickness of 1 mm, both fracture and necking contributions have the same order of magnitude in most of the metals investigated. A model is developed in order to independently evaluate the work of necking, which successfully predicts the experimental values. Furthermore, it enables the fracture energy to be derived from tests performed with only one specimen thickness. In a second modelling step, the work of fracture is computed using an enhanced void growth model valid in the quasi plane stress regime. The fracture energy varies linearly with the yield stress and void spacing and is a strong function of the hardening exponent and initial void volume fraction. The coupling of the two models allows the relative contributions of necking versus fracture to be quantified with respect to (i) the two length scales involved in this problem, i.e. the void spacing and the plate thickness, and (ii) the flow properties of the material. Each term can dominate depending on the properties of the material which explains the different behaviours reported in the literature about thin plate fracture toughness and its dependence with thickness.

Sheet Metal Department Sign

This is a black and white photograph of a sign for the Sheet Metal Department of the New York Trade School likely created by the department. It contains ornate metal work and displays the year 1938, probably the beginning year of the Sheet Metal Department.

Sheet Metal Department Students at Work

Students in the Sheet Metal Department at the New York Trade School are shown working on ductwork in a classroom at the school. Black and white photograph.

Sheet Metal Department

This is a view of a classroom in the Sheet Metal Department at the New York Trade School. Students are shown doing a variety of different tasks in the large room. Black and white photograph.

Sheet Metal Students at Work

A class of sheet metal students are shown working in this black and white photograph.

Nat Gold, Sheet Metal Graduate from the New York Trade School

Nat Gold graduated from the Sheet Metal program at the New York Trade School in 1942. He is represented here in the sheet metal shop he owns. Notice the blueprints for the White Plains Senior High School hanging on the wall behind him. Original caption reads, "Shop Owner, Brook Sheet Metal Inc. Nat Gold - Sheet Metal 1942, represents one of many Sheet Metal graduates who became owners of their own business." Black and white photograph.

Design and validation of a sheet metal shearing experimental procedure

Throughout the industrial processes of sheet metal manufacturing and refining, shear cutting is widely used for its speed and cost advantages over competing cutting methods. Industrial shears may include some force measurement possibilities, but the force is most likely influenced by friction losses between shear tool and the point of measurement, and are in general not showing the actual force applied to the sheet. Well defined shears and accurate measurements of force and shear tool position are important for understanding the influence of shear parameters. Accurate experimental data are also necessary for calibration of numerical shear models. Here, a dedicated laboratory set-up with well defined geometry and movement in the shear, and high measurability in terms of force and geometry is designed, built and verified. Parameters important to the shear process are studied with perturbation analysis techniques and requirements on input parameter accuracy are formulated to meet experimental output demands. Input parameters in shearing are mostly geometric parameters, but also material properties and contact conditions. Based on the accuracy requirements, a symmetric experiment with internal balancing of forces is constructed to avoid guides and corresponding friction losses. Finally, the experimental procedure is validated through shearing of a medium grade steel. With the obtained experimental set-up performance, force changes as result of changes in studied input parameters are distinguishable down to a level of 1%.

Sheet Metal Examples

A wall in the Sheet Metal Department at the New York Trade School shows many examples of duct work, pipe, and decorative metal work that students learn to produce. Black and white photograph that is starting to fade.

Graduate of the Sheet Metal Department, Thomas Carlough

A 1946 graduate of the Sheet Metal Department, Thomas Carlough is pictured at work at the Triangle Sheet Metal Works, Inc. Original caption reads, "Thomas Carlough - Sheet Metal 1946. The Sheet Metal Draftsman lays out the duct work etc, for the ventilation and Air Conditioning of buildings." Black and white photograph with caption adhered to reverse.

Graduate of the Sheet Metal Department, John Loonie

John Loonie, a graduate of the Sheet Metal Department of the New York Trade School, is pictured welding at work in the Triangle Sheet Metal Works Inc. Original caption reads, "John Loonie - Sheet Metal 1955, one of the Sheet Metal workers employed at the Triangle Sheet Metal Works, qualified to weld." Black and white photograph with caption adhered to reverse.

Students in the Sheet Metal Department at Work

A view of students at work in a classroom in the Sheet Metal Department at the New York Trade School. Black and white photograph.

Graduate of the Sheet Metal Sheet Metal Department David Harning

David Harning graduated from the Sheet Metal Department in 1957 and is shown in his position as Sheet Metal Cutter at the Triangle Sheet Metal Works Inc. Original caption reads, "David Harning - Sheet Metal 1957, is shown at his bench where he lays out all types of Sheet Metal pieces. These pieces will be constructed by other Sheet Metal Workers." Black and white photograph with captioned adhered to reverse.

MATHEMATICAL MODELS AND POLYHEDRAL STUDIES FOR INTEGRAL SHEET METAL DESIGN

We deal with the optimization of the production of branched sheet metal products. New forming techniques for sheet metal give rise to a wide variety of possible profiles and possible ways of production. In particular, we show how the problem of producing a given profile geometry can be modeled as a discrete optimization problem. We provide a theoretical analysis of the model in order to improve its solution time. In this context we give the complete convex hull description of some substructures of the underlying polyhedron. Moreover, we introduce a new class of facet-defining inequalities that represent connectivity constraints for the profile and show how these inequalities can be separated in polynomial time. Finally, we present numerical results for various test instances, both real-world and academic examples.