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%.

Acoustic condition monitoring for cold metal forming

One of the most important objectives of cold metal forming research is to develop techniques that enable better manufacturing efficiencies. Within this monitoring of tooling condition is vital to providing high quality manufacturing. The objective of this research is to determine the signature derived from Acoustic Emission (AE) sensors, in order to establish the current condition of a machine tool, as applied to bolt-making. From here we aim to develop and implement an on-line condition monitoring tool for the cold forming process. A review of the literature has shown that much research into AE has been successfully applied in metal cutting operations; such as milling, drilling and turning, but little research has been done related to metal forming. This appears to be due to the complexity of obtaining consistent signals using Acoustic Emission systems, because the presence of noise in many forms. This paper will detail many of the AE signals acquired and analysed through our research. The extensive results indicate this form of condition monitoring is not suitable for metal forming in its current configuration. Further tests are proposed to enable such research to move forward, so a condition monitoring system can be established.

The effect of clamping sequence on dimensional variability in sheet metal assembly

Finite element (FE) modelling techniques have become a popular tool for exploring welding and clamping sequence dependence in sheet metal assemblies. In the current paper, the dimensional variability associated with different assembly clamping sequences is investigated with a FE contact modelling approach implemented in the commercial code Abaqus. A simplified channel section assembly consisting of a top hat and bottom plate is the case study investigated. Expected variation modes of bow and twist were used to simulate key variability sources in the main structural component under investigation; the top hat of the channel section. It was found that final assembly variability can change considerably depending on clamp sequence selection. It was also found that different clamp sequences can control particular modes of variation better than others, and that there is not one particular clamping sequence that is the best for containing all variation modes. An adaptable assembly process is therefore suggested, where given the shape of input components the best available clamping sequence is selected. Comparison of the performance of the proposed adaptable clamping sequence to traditional fixed clamping sequences shows improvements for the dimensional control of variability in non-rigid components. While introducing such a method in production would require inspection of each component being assembled and investigation of the alternative clamping sequences, given access to fast and detailed dimensional inspection technology such as optical coordinate measuring machines (OCMM's), the approach shows promise for future application.

Identifying variation in sheet metal stamping

This work looks at two different “Design of Experiments”(DoE) methods for defining an operating window in the sheet metal stamping process. The first involves the use of replicates at the different experimental points, while the second is a nonreplicated method. The two methods are compared by looking at the relationship results produced and the indication of variation in the process. It is found that the results from both the methods are very similar. However, the replicated method provides a greater level of confidence in the results. In the stamping process, where performing large numbers of replicates is expensive in both time and money, the nonreplicated method provides a cost effective way of understanding the process.

Computer aided ultrasonic thickness strain analysis of automotive sheet metal stampings using FEA information

This paper discusses a computer-aided methodology for thickness strain analysis (TSA) of sheet metal stampings using geometry and strain information that is extracted from finite element analysis (FEA) results. The system utilises both FEA results and an ultrasonic gauge capability expert system to assist press shop personnel, providing them with capabilities such as optimum measurement point location and an estimate of gauge error. Key advantages of this enhanced TSA methodology are related to overall efficiency and accuracy gains.

Galling reduction through die surface treatment - testing three treatments for sheet metal stamping

This brief article describes how tool galling occurs in stamping and describes results of tests on how TiCN, Hard-Cr, and CrCN were used on sample parts to help reduce galling.

Simulation of contact pressure in sheet metal trimming/blanking process

In the car body stamping process, trim/blank die cutting edges are subjected to very high tribological loads that result in loss of tool material from both the punch and die cutting edges. According to Archard’s wear model, normal contact force and sliding distance directly affects the wear. Therefore, knowledge of the acting forces on local contact areas has a pivotal role towards the prediction of tool wear. This paper presents a finite element modelling approach to determining the contact pressure distribution on the tool cutting edges during a trimming/blanking process. Characteristic areas on sheared edge profile, variation of punch force and high contact pressures affected areas have also been analysed.

Experimental analysis of friction in forming automotive coated steels

The thesis addressed and answered a number of key issues in the experimental analysis of friction in sheet forming operations. Conventional friction theories were linked with the properties of sheet coatings and the process geometries. Newly derived mathematical models extended the analysis of friction in sheet metal forming applications.