UNIT-5

EXTRUSION AND SHEET METAL WORK

DESIGN GUIDELINES FOR EXTRUDED SECTIONS:
Extruded sections are commonly used in construction, manufacturing, and a variety of other
applications. The following are some general design guidelines for extruded sections:
1. Material selection: The choice of material is critical for extruded sections as it can affect
the strength, durability, and other properties of the product. It is important to choose a
material that can withstand the forces and stresses it will be subjected to in the
application.
2. Cross-sectional design: The cross-sectional design of the extruded section should be
carefully considered to ensure that it provides the required strength and functionality.
The shape should be designed to minimize stress concentrations and ensure even
distribution of forces.
3. Wall thickness: The wall thickness of the extruded section should be uniform to ensure
consistent strength throughout the section. Varying wall thickness can result in uneven
stress distribution and weaker areas.
4. Fillets and radii: Adding fillets and radii to the corners of the extruded section can help
to reduce stress concentrations and prevent cracking or deformation. The size of the
fillets and radii should be carefully chosen based on the intended application and
material.
5. Tolerances: Tolerances are important in extruded section design to ensure that the
finished product meets the required specifications. Tolerances should be considered for
dimensions, wall thickness, and other critical features.
6. Finishing: The extruded section may require finishing processes such as machining,
polishing, or coating to achieve the desired surface finish and properties. The finishing
process should be carefully considered during the design stage to ensure that the final
product meets the required specifications.
7. Die design: The die design is critical in extrusion processes as it affects the final shape,
dimensions, and quality of the extruded section. The die should be designed to minimize
defects such as surface finish, distortion, or warping.
8. Design for manufacturability: The extruded section design should be optimized for
manufacturing to ensure that the process is efficient and cost-effective. Factors such as
the number of operations, material utilization, and die design should be considered
during the design stage.
9. Testing and validation: The extruded section design should be validated through testing
to ensure that it meets the required specifications and performance requirements.
Testing should be performed on prototypes or samples to identify any potential issues
and make necessary adjustments.
 ➢ DESIGN PRINCIPLES OF PUNCHING
Here are some design guidelines for punching operations:
1. Material selection: The material being punched should be carefully selected to ensure
that it can be punched without damaging the equipment or the material itself. The
thickness, hardness, and ductility of the material should be taken into consideration
when selecting the appropriate punching equipment.
2. Hole placement and size: The placement and size of the holes being punched should be
carefully considered to ensure that they meet the desired specifications. The size of the
holes should be selected based on the thickness and type of material being punched, as
well as the intended use of the punched part. The placement of the holes should be
carefully measured and marked to ensure accuracy and consistency.
3. Tooling selection: The appropriate punch and die set should be selected based on the
material being punched, the size and placement of the holes, and the desired result. The
punch and die set should be made of high-quality materials and should be properly
maintained to ensure optimal performance.
4. Machine selection: The punching machine should be selected based on the size and
thickness of the material being punched, as well as the size and placement of the holes.
The machine should be capable of producing the desired result while minimizing
damage to the equipment or the material.
5. Process design: The process for punching should be carefully designed to ensure
efficiency and consistency. The material should be properly aligned and supported, and
the punching equipment should be properly lubricated and adjusted. The process should
be carefully monitored to ensure that the desired result is achieved.
6. Quality control: Quality control measures should be put in place to ensure that the
punched parts meet the desired specifications. The punched parts should be carefully
inspected for accuracy, consistency, and quality, and any defects should be identified
and addressed promptly.
Overall, careful consideration and attention to detail are essential for successful punching
operations. By following these design guidelines, punching operations can be performed safely
and efficiently, with high-quality results.
➢ DESIGN PRINCIPLES OF BLANKING
Blanking is a process used to cut flat pieces of material into specific shapes. Here are some
design guidelines for blanking:
1. Material selection: The material being blanked should be carefully selected to ensure
that it can be cut without damaging the equipment or the material itself. The thickness,
hardness, and ductility of the material should be taken into consideration when selecting
the appropriate blanking equipment.
2. Part design: The part design should be carefully considered to ensure that the desired
shape can be cut efficiently and accurately. The shape and size of the part should be
 designed with the blanking equipment in mind, taking into consideration factors such
as material thickness and type, cutting blade design, and cutting force requirements.
3. Tooling selection: The appropriate cutting blade and die set should be selected based
on the material being blanked, the size and shape of the part, and the desired result. The
cutting blade and die set should be made of high-quality materials and should be
properly maintained to ensure optimal performance.
4. Machine selection: The blanking machine should be selected based on the size and
thickness of the material being blanked, as well as the size and shape of the part. The
machine should be capable of producing the desired result while minimizing damage
to the equipment or the material.
5. Process design: The process for blanking should be carefully designed to ensure
efficiency and consistency. The material should be properly aligned and supported, and
the blanking equipment should be properly lubricated and adjusted. The process should
be carefully monitored to ensure that the desired result is achieved.
6. Quality control: Quality control measures should be put in place to ensure that the
blanked parts meet the desired specifications. The blanked parts should be carefully
inspected for accuracy, consistency, and quality, and any defects should be identified
and addressed promptly.
➢ DESIGN PRINCIPLES OF BENDING
Bending is a process used to reshape metal or other materials into a new form. Here are some
design principles of bending:
1. Material selection: The material being bent should be carefully selected to ensure that it can
be bent without damaging the material or the equipment. The thickness, hardness, and ductility
of the material should be taken into consideration when selecting the appropriate bending
equipment.
2. Tooling design: The design of the bending tool is critical to the success of the bending
operation. The bending tool should be properly designed to ensure that it can accurately and
consistently bend the material to the desired angle and radius. The tooling should also be
properly maintained to ensure optimal performance.
3. Machine selection: The bending machine should be selected based on the size and thickness
of the material being bent, as well as the desired bend angle and radius. The machine should
be capable of producing the desired result while minimizing damage to the equipment or the
material.
4. Process design: The process for bending should be carefully designed to ensure efficiency
and consistency. The material should be properly aligned and supported, and the bending
equipment should be properly lubricated and adjusted. The process should be carefully
monitored to ensure that the desired result is achieved.
5. Bend radius and angle: The bend radius and angle should be carefully considered when
designing the bending operation. The material should be bent to the desired angle and radius
without cracking or tearing. The radius of the bend should be selected based on the thickness
and type of material being bent.
6. Operator training: Proper training for the operator is essential to ensure safe and efficient
operation of the bending equipment. The operator should be trained in the safe use of the
equipment, as well as proper material handling techniques and troubleshooting skills. Regular
training and refresher courses should be provided to ensure the operator's skills remain up to
date.
➢ DESIGN PRINCIPLES OF DEEP DRAWING
Deep drawing is a metal forming process that involves stretching a sheet of metal into a three-
dimensional shape. Here are some design principles of deep drawing:
1. Material selection: The material being deep drawn should be carefully selected to
ensure that it can be formed into the desired shape without cracking or tearing. The
thickness, hardness, and ductility of the material should be taken into consideration
when selecting the appropriate deep drawing equipment.
2. Tooling design: The design of the deep drawing tooling is critical to the success of the
operation. The tooling should be properly designed to ensure that it can accurately and
consistently form the material into the desired shape. The tooling should also be
properly maintained to ensure optimal performance.
3. Machine selection: The deep drawing machine should be selected based on the size and
thickness of the material being formed, as well as the desired shape and depth of the
draw. The machine should be capable of producing the desired result while minimizing
damage to the equipment or the material.
4. Process design: The process for deep drawing should be carefully designed to ensure
efficiency and consistency. The material should be properly aligned and supported, and
the deep drawing equipment should be properly lubricated and adjusted. The process
should be carefully monitored to ensure that the desired result is achieved.
5. Draw ratio: The draw ratio, which is the ratio of the depth of the draw to the diameter
of the blank, should be carefully considered when designing the deep drawing
operation. The draw ratio should be selected based on the thickness and type of material
being drawn, as well as the desired shape of the finished product.
6. Operator training: Proper training for the operator is essential to ensure safe and
efficient operation of the deep drawing equipment. The operator should be trained in
the safe use of the equipment, as well as proper material handling techniques and
troubleshooting skills. Regular training and refresher courses should be provided to
ensure the operator's skills remain up to date.
➢ KEELER GOODMAN FORMING LINE DIAGRAM
A forming limit diagram, also known as a forming limit curve, is used in sheet metal forming
for predicting forming behaviour of sheet metal. The diagram attempts to provide a graphical
description of material failure tests, such as a punched dome test.
In order to determine whether a given region has failed, a mechanical test is performed. The
mechanical test is performed by placing a circular mark on the work piece prior to deformation,
and then measuring the post-deformation ellipse that is generated from the action on this circle.
By repeating the mechanical test to generate a range of stress states, the formability limit
diagram can be generated as a line at which failure is onset.
The semi-axes of the ellipse formed in this circle allow for the measurement of relative strain in
two primary directions, known as the major and minor directions, which correspond to the
major and minor semi-axes of the ellipse. Under the assumption of path independent strain, the
relative strains will reach a critical value at which deformations occur. Through repeated
measurements, the shape of the curve can be obtained experimentally. Alternately, a
formability limit diagram can be generated by mapping the shape of a failure criterion into the
formability limit domain. How ever the diagram is obtained, the resultant diagram provides a
tool for the determination as to whether a given cold forming process will result in failure or
not. Such information is critical in the design of forming processes, and is therefore
fundamental to the design of sheet metal forming processes. Through the establishment of
forming limit diagrams for a range of alloys, the forming process and alloy behaviour can be
matched at the metalworking design time by the process engineer.