Knowing how to design sheet metal parts is a key skill for design engineer in designing mechanical products
Sheet metal components are very commonly used in products today, Learning how to design sheet metal components is important skillset for versatile design engineer.
What should we learn?
Understand and gain insight on the processes - There are multiple number of processes by which sheet metal can be bent, formed, rolled. Knowing them is key to deciding which is most suitable for a design
Bending Parameters in design
Understand the material properties and their deviations.
Understand the mechanics of plastic metal forming.
Understand the forming and bending limits of sheet metal (not all materials can be formed into any geometry as desired)
Design for Manufacture and ease of assembly
Formability, Bendability
Design for Sheet meta manufacturing – Guidelines and best practices
Sheet metal Concept development
Engineering analysis
Practical application and projects
General sequence of operations includes
Rolling from Billets
Blanking
Bending
Forming
Blanking operation :
Bending processes:
Forming process :
Flanges are common design features in sheet metal.
Due to the low thickness sheet metal parts require stiffening.
Using dimples and beads, sheet metal parts are stiffened in forming
A sheet metal bracket in Vehicle Chassis
Combination of Forming and Bending
More topics to learn:
The Theory behind Forming and Bending
What are Forming Limit diagrams? How are they created?
Bending allowances calculation
Minimum Bend radius
K factor, Neutral axis, Bend allowance
The concept of Spring-back and ways to reduce it
Deep drawing process and the design considerations
Joining processes and their comparison
To learn about Sheet metal design in deep here is a course which can help :
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