SHEET METAL DESIGN

  • By Shubham Baghel
  • May 21, 2021
  • AutoCAD

Sheet Metal Fabrication is that the process of forming parts from a metal sheet by punching, cutting, stamping, and bending. 3D CAD files are converted into machine language, which controls a machine to exactly cut and form the sheets into the ultimate part.

Sheet Metal Operations

                     The different sorts of sheet operations can fall into two different categories:

Cutting operations

Simply put, cutting operations cause the sheet to be stressed beyond its ultimate strength therefore breaking its structure and separating into different parts.

  • Shearing Operation

Shearing is that the process of separating the sheet into two or more pieces, normally by cutting along a line. Commonly wont to dig rectangular shapes but can produce other shaped parts.

 

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  • Blanking & Fine Blanking Operation

Blanking is that the process of ablation a predefined shape from the sheet metal; the part that’s punched out is understood because the blank and is that the required product, the metal left behind is waste. Fine blanking is analogous but provides more accuracy, with smooth edges and no distortion by applying clamping force and using small and shut tolerances.

  • Punching Operation

Punching is that the same process as blanking, but the specified product is that the metal left behind, instead of the part that’s punched out. It uses an equivalent punching press and punch and die operation, it’s just the opposing desired product.

  • Piercing Operation

Piercing is that the process of cutting small, cylindrical holes within the sheet while removing little or no quantity of fabric. This is often done by employing a bullet shaped punch during the punch and die operation.

  • Perforating Operation

Perforation may be a similar process to piercing, but the holes aren’t usually round in shape. Perforating commonly consists of quite one hole that has been punched during a pattern.

  • Slotting Operation

Slotting is that the process of cutting rectangular holes onto sheet, sometimes unfinished.

 

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  • Notching Operation

Notching is that the process where shapes are cut from the sides of the sheet metal; removing and trimming and creating notches at the sting.

Forming operations.

Forming operations cause stress below the sheet metal’s ultimate strength, leading to distortion.

  • Bending Operation

Bending is that the process of re-modeling the straight sheet into a curved form. There are variety of various sorts of bending such as:

  • Channel Bending
  • Offset Bending
  • Edge Bending
  • U-Bending
  • V-Bending

 Basic Parameters of Sheet Metal

All sheet operations have a gaggle of common parameters. You’ll set default values for a few of those parameters.

The main operation of working with the sheet is bending. Many operations create geometry, which is that the results of several bends in several ways or operations on the brink of bending but having their own characteristics. Accordingly, the dialogs of commands for working with sheets contain bending parameters that are equivalent for several operations.

Some parameters aren’t available to the user during a single operation, which is explained by the logic of constructing the geometry and therefore the capabilities of the command as an analog of a true technological operation.

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Radius

The parameter sets the worth of the bend radius. The parameter features a custom default value. The parameter features a manipulator within the 3D scene.

If you employ a profile that sets the section of the sheet, the radius value will specify the fillet at the non-rounded corners of the profile.

Angle

The parameter sets the worth of the bend angle, which determines the slope of the wall of the sheet part. The parameter doesn’t have a custom default value. For many of the operations, the default value of the parameter is 90°. The Toggle bend direction option allows inverting the worth. The parameter features a manipulator within the 3D scene 

K-Factor

The parameter allows specifying the neutral layer coefficient. The parameter controls neutral factor definition upon part bending and unbending. The parameter is required for all operations that have an unfolding. The neutral layer of a workpiece is its longitudinal section, whose geometry doesn’t change during bending.

The neutral layer coefficient value can either be entered by the user or defined by the system automatically, supported the table of Neutral factors versus “bend radius/workpiece thickness” ratio. The definition is controlled by a radial-button switch. To define the neutral layer coefficient automatically, set the switcher to the Autodetect position. Setting the opposite button allows entering an arbitrary number within the range from 0 to 1. the worth “0” means the neutral layer coincides with the workpiece face selected for bending, while “1” sets the neutral layer on the other face of the workpiece.

 

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Bend Relief

A group of parameters by which special grooves are often defined to scale back stresses within the metal, concentrated at the bending angles.

Bending operations allow you to make a Bend Relief automatically when performing certain operations. Reliefs are divided into Corner and Isolating. Isolating relief allows you to get rid of stress within the bendable flange. Corner relief allows you to get rid of stress at the joint of the flanges and walls. Corner reliefs are often specified with a separate Corner command.

Solidworks for sheet metal design

                     Solidworks contains two separate methods for working in sheet metal. In one method you can use dedicated sheet metal features from the start, and in the other method you build a part using thin features and other generic modelling tools, and then tell solidworks it is sheet metal so you can flatten it. The reason for two methods is that the generic modelling method came first and then solidworks introduced a more powerful set of dedicated sheet metal features. You can use these tools together or separately, and either way you get an accurately flattened part at the end.

                 Sheet metal tools do not always represent real world sheet metal from bending processes are too complex to easily represent in a CAD model. So there are times you still have to use your imagination a little bit.

                   The main point is that the flat patterns are always accurate because sheet metal is usually fabricated using 2D data.

Since many industries require a good range of sheet parts to deal with or enclose their designs, SOLIDWORKS makes a versatile design approach possible. With SOLIDWORKS you can

  • Convert SOLIDWORKS or imported CAD models
  • create original parts or design around a gaggle of parts 
  • Generate Base, Edge, 
  • Meter, and Swept Flanges 
  • Generate bends, including Lofted Bends, Sketched Bends, and more Use Bend Tables for bend allowance/bend deduction 
  • Use Forming Tools to make features like ribs, louvers, lances, embosses, and extruded flanges 
  • Add weld details to sheet parts on models or drawings 
  • Automatically flatten parts to get flat patterns for manufacturing with bend compensation
  • Automatically estimate sheet part manufacturing cost as you design. 

    Author:- Shinde, Vaishnavi

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