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Sheet Metal Design
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Introduction to the course
Design to production cycle
Why sheet metal?
Why Knowledge of Process is important for Designer?
Knowledge and Skills required to Design effectively
Sheet metal Rolling
Material selection
Material properties
Steel vs Aluminum
Modulus
Hardness
Toughness and Strength
Comparison between Hardness, Toughness and Strength
Shearing Operation
Common Processes
Basic Stamping process
Scrap in Sheet metal and Shaving operation
Cutting operations
What is Plastic Deformation?
Stress Strain Curve
Plastic Elongation in Testing
Anisotropy
Grain Size
Formability Test
Major and Minor Axis of deformation
Major Strain and Minor Strain
Forming Limit Diagram
Section Quiz
Bending Process
Bend Parameters and Bend allowance
Neutral Axis in Bending and K factor
Material Effects in Bending
Minimum Bend Radius
Tensile Reduction of Area
Factors that Affect Bendability
Factors that Affect Bendability - Material Inclusions
Types of Flanging
Beading operation
Spring-back and Effects
Negative Springback
Counter-acting Springback
Wrinkling in Sheet metal
Deep Drawing Operation
Deep drawing Details
Deep drawing Practice
Ironing and Redrawing
Section quiz
Hydroforming
Tube Hydroforming
Hydroforming - Why is it used in Automotive and Drawbacks
Spinning
Stretch Forming
Tube Bending
Roll Forming
Embossing and Coining
Section Quiz
Welding
Fasteners
Fasteners vs Welding
Simple and Compound Dies
Progressive Dies
Transfer Dies
Press Selection and Design aspects
Economics of Sheet metal Processing
Section quiz
Manufacturing Cost
Blank Design
Bend and Grain Direction
Stress Concentration
Design Guidelines for Holes and Tabs
Design Guidelines for Bend relief 1
Design Guidelines for Bend relief 2
Design Guidelines for Flange near Bends
Design Guidelines for holes near Bends and edges
Design Guidelines for holes near Bends and edges
Corner Finishing
Notches of Stretch Flange
Tooling Holes
Avoiding Deep channels in Bending
Tolerance in Sheet metal and Factors
Beads and Dimples to increase Stiffness
Alignment of Holes in Bent parts
Non-Formable parts
Maintaining orientation and flatness of surfaces
Formability Issues
Transitions
Considerations in Sheet metal design
Summary - General guidelines for Sheet metal design
Section Quiz
Introduction - Projects
Input Files
Project 1 - Problem statement, Input and requirements
Project 1 - CAD Design Part 1
Project 1 - CAD Design Part 2
Project 1 - CAD Design Part 3
Project 1 - Review and Summary
Project 2 - Problem statement and Input
Project 2 - CAD design
Project 2 - Review
Project 3 - Problem statement and Input
Project 3 - CAD design Iteration 1
Project 3 - CAD design Iteration 2- with stiffener
Project 3 - Review
Project 4- Problem statement and Input
Project 4 - CAD design
Project 4 - Review
Fusion 360 Sheet metal bracket CAD workflow 1
Fusion 360 Sheet metal bracket CAD workflow 2
Introduction
Introduction to the course
Design to production cycle
Why sheet metal?
Why Knowledge of Process is important for Designer?
Preview
Knowledge and Skills required to Design effectively
Materials
Sheet metal Rolling
Material selection
Material properties
Steel vs Aluminum
Modulus
Hardness
Toughness and Strength
Comparison between Hardness, Toughness and Strength
Common processes
Shearing Operation
Common Processes
Basic Stamping process
Scrap in Sheet metal and Shaving operation
Cutting operations
Theory of Plastic Deformation
What is Plastic Deformation?
Stress Strain Curve
Preview
Plastic Elongation in Testing
Anisotropy
Grain Size
Formability
Formability Test
Major and Minor Axis of deformation
Major Strain and Minor Strain
Forming Limit Diagram
Preview
Section Quiz
Bending
Bending Process
Bend Parameters and Bend allowance
Neutral Axis in Bending and K factor
Material Effects in Bending
Minimum Bend Radius
Tensile Reduction of Area
Factors that Affect Bendability
Factors that Affect Bendability - Material Inclusions
Types of Flanging
Beading operation
Springback and Wrinkling
Spring-back and Effects
Negative Springback
Counter-acting Springback
Wrinkling in Sheet metal
Deep drawing
Deep Drawing Operation
Deep drawing Details
Deep drawing Practice
Ironing and Redrawing
Section quiz
Other Operations
Hydroforming
Tube Hydroforming
Hydroforming - Why is it used in Automotive and Drawbacks
Spinning
Stretch Forming
Tube Bending
Roll Forming
Embossing and Coining
Section Quiz
Sheet metal Joining
Welding
Fasteners
Fasteners vs Welding
Tools and Equipment
Simple and Compound Dies
Progressive Dies
Transfer Dies
Press Selection and Design aspects
Economics of Sheet metal Processing
Section quiz
Design Considerations
Manufacturing Cost
Blank Design
Bend and Grain Direction
Stress Concentration
Design Guidelines for Holes and Tabs
Design Guidelines for Bend relief 1
Design Guidelines for Bend relief 2
Design Guidelines for Flange near Bends
Design Guidelines for holes near Bends and edges
Design Guidelines for holes near Bends and edges
Corner Finishing
Notches of Stretch Flange
Tooling Holes
Avoiding Deep channels in Bending
Tolerance in Sheet metal and Factors
Beads and Dimples to increase Stiffness
Alignment of Holes in Bent parts
Non-Formable parts
Maintaining orientation and flatness of surfaces
Formability Issues
Transitions
Considerations in Sheet metal design
Summary - General guidelines for Sheet metal design
Section Quiz
Design Projects
Introduction - Projects
Input Files
Project 1 - Problem statement, Input and requirements
Project 1 - CAD Design Part 1
Project 1 - CAD Design Part 2
Project 1 - CAD Design Part 3
Project 1 - Review and Summary
Project 2 - Problem statement and Input
Project 2 - CAD design
Project 2 - Review
Project 3 - Problem statement and Input
Project 3 - CAD design Iteration 1
Project 3 - CAD design Iteration 2- with stiffener
Project 3 - Review
Project 4- Problem statement and Input
Project 4 - CAD design
Project 4 - Review
CAD design in Fusion 360 using Surface tools
Fusion 360 Sheet metal bracket CAD workflow 1
Fusion 360 Sheet metal bracket CAD workflow 2
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