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Sheet Metal Technology is written in Dave’s unique style with the beginner or vocational student in mind as he demonstrates how a product idea is conceived, developed and then produced by a single craftsman with basic tools. Subjects covered are safety in the shop, use of tools, layout and pattern development, various ways of forming and joining metal along with edging methods, corner systems and panel reinforcement. You will be introduced to the basic sheet metal shop where you will learn about various methods of forming sheet metal and in some instances even constructing your own tools including a rather unique and functional 24" sheet metal brake constructed of hardwood. The final chapter opens with a mass production operation set up to demonstrate the efficiency and economy of modern industrial technology. Then further projects are progressively introduced as skill is acquired. Such projects as a dustpan for the shop, a handy tool tote tray as well as plans for single and double hinge tool boxes. By this time you are an advanced student and ready to construct the unique portable charcoal grill and the impressive three drawer tool chest from the plans provided. Dave Gingery brings it all within your grasp and you will be amazed at what can be produced with tin snips, standard measuring tools and a 24" sheet metal brake.
By an engineer with decades of practical manufacturing experience, this book is a complete modern guide to sheet metal forming processes and die design - still the most commonly used methodology for the mass-production manufacture of aircraft, automobiles, and complex high-precision parts. It illustrates several different approaches to this intricate field by taking the reader through the "hows" and "whys" of product analysis, as well as the techniques for blanking, punching, bending, deep drawing, stretching, material economy, strip design, movement of metal during stamping, and tooling. While concentrating on simple, applicable engineering methods rather than complex numerical techniques, this practical reference makes it easier for readers to understand the subject by using numerous illustrations, tables, and charts. Emphasizes the influence of materials as an aid to understanding manufacturing processes and operations. Features the essential mathematical formulas and calculations needed for various die operations and performance evaluation. Shows the comparative advantages and liabilities for each manufacturing process and operation. Offers a complete picture of the knowledge and skills needed for the effective design of dies for sheet-metal forming processes highlighted with illustrative examples. Provides properties and typical applications of selected tool and die materials for various die parts.
Process Control for Sheet-Metal Stamping presents a comprehensive and structured approach to the design and implementation of controllers for the sheet metal stamping process. The use of process control for sheet-metal stamping greatly reduces defects in deep-drawn parts and can also yield large material savings from reduced scrap. Sheet-metal forming is a complex process and most often characterized by partial differential equations that are numerically solved using finite-element techniques. In this book, twenty years of academic research are reviewed and the resulting technology transitioned to the industrial environment. The sheet-metal stamping process is modeled in a manner suitable for multiple-input multiple-output control system design, with commercially available sensors and actuators. These models are then used to design adaptive controllers and real-time controller implementation is discussed. Finally, experimental results from actual shop floor deployment are presented along with ideas for further improvement of the technology. Process Control for Sheet-Metal Stamping allows the reader to design and implement process controllers in a typical manufacturing environment by retrofitting standard hydraulic or mechanical stamping presses and as such will be of interest to practising engineers working in metal-working, automotive and aeronautical industries. Academic researchers studying improvements in process control and how these affect the industries in which they are applied will also find the text of value.
The concept of virtual manufacturing has been developed in order to increase the industrial performances, being one of the most ef cient ways of reducing the m- ufacturing times and improving the quality of the products. Numerical simulation of metal forming processes, as a component of the virtual manufacturing process, has a very important contribution to the reduction of the lead time. The nite element method is currently the most widely used numerical procedure for s- ulating sheet metal forming processes. The accuracy of the simulation programs used in industry is in uenced by the constitutive models and the forming limit curves models incorporated in their structure. From the above discussion, we can distinguish a very strong connection between virtual manufacturing as a general concept, ?nite element method as a numerical analysis instrument and constitutive laws,aswellas forming limit curves as a speci city of the sheet metal forming processes. Consequently, the material modeling is strategic when models of reality have to be built. The book gives a synthetic presentation of the research performed in the eld of sheet metal forming simulation during more than 20 years by the members of three international teams: the Research Centre on Sheet Metal Forming—CERTETA (Technical University of Cluj-Napoca, Romania); AutoForm Company from Zürich, Switzerland and VOLVO automotive company from Sweden. The rst chapter presents an overview of different Finite Element (FE) formu- tions used for sheet metal forming simulation, now and in the past.