casting_forming-sheet metal process 铸造,金属成形,钣金.ppt

Stages in Closed-Die Forging [source:Kalpakjian Schmid] Quality of forged parts Stronger/tougher than cast/machined parts of same material Surface finish/Dimensional control: Better than casting (typically) [source:] Extrusion Metal forced/squeezed out through a hole (die) Typical use: ductile metals (Cu, Steel, Al, Mg), Plastics, Rubbers Common products: Al frames of white-boards, doors, windows, … [source:] Extrusion: Schematic, Dies Exercise: how can we get hollow parts? Drawing Commonly used to make wires from round bars Similar to extrusion, except: pulling force is applied AUDI engine block V6 engine block BMW cylinder head Brake assembly Impellers Crank Shaft Also see: /engine7.htm Traditional Manufacturing Processes Casting Forming Sheet metal processing Cutting Joining Powder- and Ceramics Processing Plastics processing Surface treatment Sheet Metal Processes Raw material: sheets of metal, rectangular, large Raw material Processing: Rolling (anisotropic properties) Processes: Shearing Punching Bending Deep drawing Shearing A large scissors action, cutting the sheet along a straight line Main use: to cut large sheet into smaller sizes for making parts. Punching Cutting tool is a round/rectangular punch, that goes through a hole, or die of same shape Punching Main uses: cutting holes in sheets; cutting sheet to required shape typical punched part nesting of parts Exercise: how to determine optimal nesting? Bending Body of Olympus E-300 camera component with multiple bending operations [image source: ] component with punching, bending, drawing operations Typical bending operations and shapes (a) (b) Sheet metal bending Planning problem: what is the sequence in which we do the bending operations? Avoid: part-tool, part-part, part-machine interference Bending mechanics Bending Planning ? what is the length of blank we must use? Ideal case: k = 0.5 Real cases: k = 0.33 ( R 2T) ~~ k = 0.5 (R 2T) Bending: cracking, anisotropic effects, Poisso