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.

Analys av förvridning vid hålning av rör : Analysis of metal torsion in rotary piercing

Hålningsprocessen är det inledande bearbetningssteget vid varmvalsning av sömlösa rör. Det är en tvärvalsningsprocess i vilken ett cylindriskt ämne valsas mellan två dubbelkoniska val¬sar över en plugg. Valsarna är snedställda med en viss mat¬ningsvinkel, vilken ger upphov till en axiell drivkraft genom ver¬ket. Hela denna pro¬cess är roterande. Detta i kombination med bl.a. de koniska valsarna leder till en förvrid¬ning av röret, dvs. en tänkt rak linje på det ingå¬ende äm¬net övergår till en spiral efter genomförd valsning. Med föreliggande uppgift är målet att studera förvridningen genom teoretisk och experimen¬tell analys. Syftet med detta är dels att få fördjupad kunskap inom området och dels att ut¬veckla en modell för pre¬diktering av förvridningen.Det experimentella arbetet är utfört på ett stål av typ Ovako 280 (SS2142). Denna mjuka stål¬sort valdes i syfte att undvika värmebehandling innan provberedning. För att visuali¬sera för¬vridningen fräs¬tes ett rakt spår längs det ingående äm¬net och hål borrades mot symmetrilinjen. De praktiska undersökningarna utfördes direkt i den löpande produktionen. Genomförda beräkningar uppvisar en längsgående förvridningsvinkel som stämmer väl över¬ens med uppmätt värde. Detta är dock under antagandet att den tangentiella hastighetskoeffi¬cienten varierar linjärt utmed deformationszonen. För en mer utvecklad modell krävs en nog¬grannare analys av kontakten mellan vals/ämne eller en grundligt genomförd uppmätning av ämnets vinkelhastighet.

Att definiera och skilja på snarlika subgenrer : Tillämpat på death- och black metal

Det är svårt att sätta ord på vad man menar när man pratar om musik. Jag är intresserad av varför det sällan går att finna definitioner av genrer när diskussionen om dem är så stark, speciellt när det gäller snarlika genrer som troligtvis är uppdelade av en eller flera anledningar. Syftet med min undersökning är att utveckla vidare kunskap om vilken betydelse det har att skilja på två snarlika subgenrer inom samma metagenre. Jag undersöker därför hur två snarlika genrer definieras och jämför dem sedan och prövar om det är av betydelse att undersöka flera aspekter av en musikgenre. Tidigare forskning föreslår att den musikaliska stilen borde undersökas likväl som kulturen och andra aspekter. En stark diskussion pågår just inom heavy metalscenen om subgenrerna inom den, därför undersöker jag subgenrerna death- och black metal. I denna undersökning använder jag Fabbris mall för genredefinition, där undersöks formella och tekniska regler, semiotiska regler, regler för beteende, sociala och ideologiska regler samt ekonomiska och juridiska regler. Reglerna har jag undersökt genom att lyssna på fonogram, titta på videoinspelningar av liveframträdande och publik samt hur aktörer inom scenerna beter sig när de inte är på scen. Jag har även analyserat låttexter och använt mig av diverse litteratur och dokumentärfilmer. Mitt resultat visar att det finns betydande anledningar till att skilja på death metal och black metal trots att de musikaliskt liknar varandra.

Sons of Northern Darkness : En fråga om stil och identitet i Black Metal-kulturen

Min uppsats har visat på black metal-stilens betydelse för fyra ungdomars identitetsskapande. Jag har med koppling till teoretiska infallsvinkar och begrepp rörande stilars och kulturers betydelse diskuterat black metal-kulturen med fokus på dess stilmässiga uttryck, dess symbolanvändande och dess innebörd för ungdomarnas självbild.I min studie har jag diskuterat och redogjort för hur black metal-kulturen kan te sig genom att förklara hur musiken låter och hur stilens uttryck i form av kläder och frisyrer kan se ut. Uppsatsen har visat på hur symboler och kodsystem används av ungdomarna inom ramen för kulturen för att markera och positionera sin identitet. Jag har i min studie även visat hur black metal-stilen kan vara ett existentiellt ställningstagande mot kommersialism och mainstreamkultur.

3D roll-forming of hat-profile with variable depth and width

The use of roll-formed products in automotive, furniture, buildings etc. increases every year due to the low part-production cost and the complicated cross-sections that can be produced. The limitation with roll-forming until recent years is that one could only produce profiles with a constant cross-section in the longitudinal direction. About eight years ago ORTIC AB [1] developed a machine in which it was possible to produce profiles with a variable width (“3D roll-forming”) for the building industry. Experimental equipment was recently built for research and prototyping of profiles with variable cross-section in both width and depth for the automotive industry. The objective with the current study is to investigate the new tooling concept that makes it possible to roll-form hat-profiles, made of ultra high strength steel, with variable cross-section in depth and width. The result shows that it is possible to produce 3D roll-formed profiles with close tolerances.

Experimental and computational investigation of the roll forming process

One of the first questions to consider when designing a new roll forming line is the number of forming steps required to produce a profile. The number depends on material properties, the cross-section geometry and tolerance requirements, but the tool designer also wants to minimize the number of forming steps in order to reduce the investment costs for the customer. There are several computer aided engineering systems on the market that can assist the tool designing process. These include more or less simple formulas to predict deformation during forming as well as the number of forming steps. In recent years it has also become possible to use finite element analysis for the design of roll forming processes. The objective of the work presented in this thesis was to answer the following question: How should the roll forming process be designed for complex geometries and/or high strength steels? The work approach included both literature studies as well as experimental and modelling work. The experimental part gave direct insight into the process and was also used to develop and validate models of the process. Starting with simple geometries and standard steels the work progressed to more complex profiles of variable depth and width, made of high strength steels. The results obtained are published in seven papers appended to this thesis. In the first study (see paper 1) a finite element model for investigating the roll forming of a U-profile was built. It was used to investigate the effect on longitudinal peak membrane strain and deformation length when yield strength increases, see paper 2 and 3. The simulations showed that the peak strain decreases whereas the deformation length increases when the yield strength increases. The studies described in paper 4 and 5 measured roll load, roll torque, springback and strain history during the U-profile forming process. The measurement results were used to validate the finite element model in paper 1. The results presented in paper 6 shows that the formability of stainless steel (e.g. AISI 301), that in the cold rolled condition has a large martensite fraction, can be substantially increased by heating the bending zone. The heated area will then become austenitic and ductile before the roll forming. Thanks to the phenomenon of strain induced martensite formation, the steel will regain the martensite content and its strength during the subsequent plastic straining. Finally, a new tooling concept for profiles with variable cross-sections is presented in paper 7. The overall conclusions of the present work are that today, it is possible to successfully develop profiles of complex geometries (3D roll forming) in high strength steels and that finite element simulation can be a useful tool in the design of the roll forming process.

Microstructural, Mechanical and Tribological Characterisation of CVD and PVD Coatings for Metal Cutting Applications

The present thesis focuses on characterisation of microstructure and the resulting mechanical and tribological properties of CVD and PVD coatings used in metal cutting applications. These thin and hard coatings are designed to improve the tribological performance of cutting tools which in metal cutting operations may result in improved cutting performance, lower energy consumption, lower production costs and lower impact on the environment.  In order to increase the understanding of the tribological behaviour of the coating systems a number of friction and wear tests have been performed and evaluated by post-test microscopy and surface analysis. Much of the work has focused on coating cohesive and adhesive strength, surface fatigue resistance, abrasive wear resistance and friction and wear behaviour under sliding contact and metal cutting conditions. The results show that the CVD deposition of accurate crystallographic phases, e.g. α-Al2O3 rather than κ-Al2O3, textures and multilayer structures can increase the wear resistance of Al2O3. However, the characteristics of the interfaces, e.g. topography as well as interfacial porosity, have a strong impact on coating adhesion and consequently on the resulting properties.  Through the deposition of well designed bonding and template layer structures the above problems may be eliminated. Also, the presence of macro-particles in PVD coatings may have a significant impact on the interfacial adhesive strength, increasing the tendency to coating spalling and lowering the surface fatigue resistance, as well as increasing the friction in sliding contacts. Finally, the CVD-Al2O3 coating topography influences the contact conditions in sliding as well as in metal cutting. In summary, the work illuminates the importance of understanding the relationships between deposition process parameters, composition and microstructure, resulting properties and tribological performance of CVD and PVD coatings and how this knowledge can be used to develop the coating materials of tomorrow.

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%.