MANUFACTURING PROCESSES

KKKM2833

Assignment

Yousef Almutairi
GA03616

Prof. Dr.ANDANASTUTI MUCHTAR

Dr. NASHRAH HANI BINTI JAMADON
1. Sheet metal forming operations produce a wide range of consumer and industrial
products, such as metal desks, appliances, aircraft fuselages, car bodies, and kitchen
utensils. What is the difference between a notching operation and a lancing operation in
sheet metal forming?

- Notching:
Similar to blanking however the full surface of punch does not cut the metal
In this operation the metal pieces are cut from the edges of a sheet

- Lancing:
In this operation, there is a cut of sheet metal through a small length and bending
this small cut portion downwards.

2. In sheet metal forming, what is meant by "fine blanking"?

- fine blanking a specialty type of metal stamping that can achieve part
characteristics such as flatness and a full sheared edge to a degree that is nearly
impossible using a conventional metal cutting or punching process.

3. How does a machine called a 'nibbler' be useful in sheet metal working?

- Nibbler is a tool for cutting sheet metal with minimal distortion. One type operates
much like a punch and die, with a blade that moves in a linear fashion against a
fixed die, removing small bits of metal and leaving a kerf approximately 6 mm
wide. Another type operates similar to tin snips, but shears the sheet along two
parallel tracks 3–6 mm apart, rolling up the waste in a tight spiral as it cuts.
Nibblers may be manual (hand operated) or powered.
4. Figure I illustrates a "beading' process in sheet metal forming. Explain several
functions of a beading process?

- It is a process in which the periphery of the sheet metal is bent into the cavity of a
die. It increases moment of inertial of the section and stiffness. It also eliminates
exposed sharp edges.

5. Powder metallurgy (PM) is a metal processing technology in which parts are

produced from metallic powders. What do you think are the reasons why powder
metallurgy has become an important commercial technology in recent years?

- is a highly flexible and robust solution to support moderate- to high-volume

component production requirements.

- minimizes scrap losses by typically using more than 97% of the starting raw
material in the finished part.

- is a demonstrated process of supporting speed-to-market.

6. What is rolling in the context of the bulk deformation processes? 

- Rolling is a deformation process in which the thickness of the workpiece is

reduced by compressive forces exerted by two opposing rolls. The rolls rotate,
thus pulling and simultaneously squeezing the workpiece between them.
Q7. In a sheet metal forming industry, vou have been assigned te produce a steel
cooking pot with the below specifications

Height of pot: 40 mm 

Inside diameter of pot: 65 mm 

You are given a sheet metal of thickness 2.5mm  with its blank diameter of 110 mm 

Determine: 

i) the drawing ratio

ii)  the reduction. 

iii) the thickness-to-diameter ratio. 

iv) Is the operation feasible? Justify your answer.

i)

ii)

iii)

iv) Yes, operation is feasible, because there is a limiting drawing ratio (LDR) after which
punch will piece a hole in blank instead of drawing.
LDR range is 1.6 to 2.3

In our Case DR = 1.69

1.6<DR<2.3