Metal Shaping Processes

As the only comprehensive text focusing on metal shaping processes, which are still the most widely used processes in the manufacture of products and structures, Metal Shaping Processes carefully presents the fundamentals of metal shaping processes with their relevant applications. The treatment of the subject matter is adequately descriptive for those unfamiliar with the various processes and yet is sufficiently analytical for an introductory academic course in manufacturing. The text, as well as the numerous formulas and illustrations in each chapter, clearly show that shaping processes, as a part of manufacturing engineering, are a complex and interdisciplinary subject. The topics are organized and presented in such a manner that they motivate and challenge students to present technically and economically viable solutions to a wide variety of questions and problems, including product design. It is the perfect textbook for students in mechanical, industrial, and manufacturing engineering programs at both the Associate Degree and Bachelor Degree programs, as well a valuable reference for manufacturing engineers (those who design, execute and maintain the equipment and tools); process engineers (those who plan and engineer the manufacturing steps, equipment, and tooling needed in production); manufacturing managers and supervisors; product design engineers; and maintenance and reliability managers and technicians. Each chapter begins with a brief highlighted outline of the topics to be described. Carefully presents the fundamentals of the particular metal-shaping process with its relevant applications within each chapter, so that the student and teacher can clearly assess the capabilities, limitation, and potentials of the process and its competitive aspects. Features sections on product design considerations, which present guidelines on design for manufacturing in many of the chapters. Offers practical, understandable explanations, even for complex processes. Includes text entries that are coded as in an outline, with these numerical designations carried over the 320 related illustrations for easy cross-referencing. Provides a dual (ISO and USA) unit system. Contains end-of-chapter Review Questions. Includes a chapter on sheet metalworking covering cutting processes; bending process; tubes and pipe bending; deep drawing processes; other sheet metal forming process (stretch forming, spinning, rubber forming, and superplatic forming and diffusion bonding). Provides a useful die classification with 15 illustrations and description; presses for sheet metalworking; and high energy-rate forming processes. A chapter on nontraditional manufacturing process discusses such important processes as mechanical energy processes (ultrasonic machining, water jet cutting); electrochemical machining processes (electrochemical machining, electrochemical grinding); thermal energy processes (electric discharge processes, laser beam machining, electron beam machining); and chemical processes (chemical milling). Part I: Casting and Molding Fundamentals of Metal Casting Metal-Casting Processes Metal Casting: Design and Materials Part II: Particulate Processing for Metals Powder Metallurgy Part III: Deformation Processes Fundamentals of Metal FormingRolling of Metals Forging. Extrusion and Drawing of Metals Sheet Metalworking Part IV: Metal Removal Processes Fundamentals of Metal Machining Machining Processes Abrasive Machining Processes Nontraditional Machining Processes Appendix Index

Metals are still the most widely used structural materials in the manufacture of products and structures. Their properties are extremely dependent on the processes they undergo to form the final product. Successful manufacturing therefore depends on a detailed knowledge of the processing of the materials involved. This highly illustrated book provides that knowledge. Metal processing is a technical subject requiring a quantitative approach. This book illustrates this approach with real case studies derived from industry. Real industrial case studies Quantitative approach Challenging student problems

The Sheet Metal/HVAC Pro Calc is a versatile calculator that enables tradesmen to calculate complex problems with dedicated key functions that are labeled in standard industry terms. The calculator has other advanced built-in construction-math functions to enable HVAC and sheet metal tradesmen to do their work alongside other trades. In addition to the built-in functions, this calculator can handle order of operation, using the parenthesis operators. It can also perform square, cube, square root, and cube root calculations. Plus, it works as a regular calculator with typical symbols. The calculator can be used to determine ArcK constant for convenient Arc length solutions. And it has an offset functions for "S-shaped" bends in ductwork. It can also help solve the layout for wrapper length, centerline radius, and the angle. Features CUSTOM HVAC & SHEET METAL functions let you simplify Test and Balance (TAB) with built-in Fan Law function: CFM, RPM, SP and BHP; velocity and velocity pressure: FPM, VP, MPS, KPa; ArcK constant for convenient Arc length solutions; and offset functions FUNCTIONS AND TERMINOLOGY consistent with sheet metal and HVAC trade terminology; x, y, r (radius), theta and Seg Radius functions; works in and converts between feet-inch-fractions, decimal feet and inches and metric also converts between polar and rectangular coordinates PARENTHESIS OPERATORS allows you to easily enter complex formulas; order of operations calculations retain familiar mathematical hierarchy as a default preference; trigonometric operation and sequence; and you can calculate square, square root, cube, and cube root; easy non-90 triangles and right-angle solutions for ductwork length and angles MEMORY STORAGE conveniently stores frequently used constants or interim solutions; Memory swap lets you easily insert stored values into current calculations and simultaneously store calculated values while recalling and displaying Memory contents; other settable User Preferences INVALUABLE TRADE TOOL PAYS FOR ITSELF by reducing headaches, saving time, and preventing expensive material errors on all your projects. Comes with a rugged shock, dust and moisture-resistant Armadillo Gear protective case, quick reference guide and complete user's guide, a long-life battery, and a one-year limited warranty.

This sourcebook presents the most important metal-working and shearing processes - and their related machines and tooling - in a concise form supplemented by ample illustrations, tables and flow charts. Practical examples show how to calculate forces and strain energy of the processes and the specific parameters of the machines, and exercises help readers improve understanding. Because much production today is automated using modern Computer Numerical Control engineering, the book covers automated flexible metal forming and handling systems. Carefully translated from the eighth revised German-language edition, Metal Forming Practise offers a valuable reference tool for students, engineers and technicians.

Whether you want to create custom or replacement parts or build an entire automobile body, this metalworking course for gearheads from best-selling automotive restoration author and professor Ed Barr will take you as far as your interests reach. Barr demystifies this seemingly black art with information on tools and basic skills and 14 customizable projects, fully illustrated with step-by-step color photography. First, you'll learn how to assemble your ideal toolkit, as well as how to build a power hammer and an English wheel. In the process, Barr will help you make informed choices based on available space and budget. Once you're all set up, he addresses the concepts of shape and form. The projects are presented in a way that you can easily apply them to their own vehicles, whatever they may be. Barr also takes the time to show how the projects can be accomplished with different available tools. As you go, you'll gain the skills and confidence for tackling the increasingly complex cases presented. Work your way up to building a fender utilizing the wheeling machine you built earlier; then move on to building a Model T speedster body and an Indy car, and later a challenging ’â??34 Plymouth fender. The book even includes common “goofs” and how to avoid and, if necessary, correct them. Written in an engaging and approachable style, Sheet Metal Shaping serves equally well as a useful supplement to Barr’s previous Professional Sheet Metal Fabrication or as a must-have standalone volume for any fabricator’s library.

Following the long tradition of the Schuler Company, the Metal For ming Handbook presents the scientific fundamentals of metal forming technology in a way which is both compact and easily understood. Thus, this book makes the theory and practice of this field accessible to teaching and practical implementation. The first Schuler "Metal Forming Handbook" was published in 1930. The last edition of 1966, already revised four times, was translated into a number of languages, and met with resounding approval around the globe. Over the last 30 years, the field of forming technology has been rad ically changed by a number of innovations. New forming techniques and extended product design possibilities have been developed and introduced. This Metal Forming Handbook has been fundamentally revised to take account of these technological changes. It is both a text book and a reference work whose initial chapters are concerned to pro vide a survey of the fundamental processes of forming technology and press design. The book then goes on to provide an in-depth study of the major fields of sheet metal forming, cutting, hydroforming and solid forming. A large number of relevant calculations offers state of the art solutions in the field of metal forming technology. In presenting tech nical explanations, particular emphasis was placed on easily under standable graphic visualization. All illustrations and diagrams were compiled using a standardized system of functionally oriented color codes with a view to aiding the reader's understanding.

Manufacturing, reduced to its simplest form, involves the sequencing of product forms through a number of different processes. Each individual step, known as an unit manufacturing process, can be viewed as the fundamental building block of a nation's manufacturing capability. A committee of the National Research Council has prepared a report to help define national priorities for research in unit processes. It contains an organizing framework for unit process families, criteria for determining the criticality of a process or manufacturing technology, examples of research opportunities, and a prioritized list of enabling technologies that can lead to the manufacture of products of superior quality at competitive costs. The study was performed under the sponsorship of the National Science Foundation and the Defense Department's Manufacturing Technology Program.

This book is a complete modern guide to sheet metal forming processes and die design - still the most commonly used methodology for the mass-production manufacture of aircraft, automobiles, and complex high-precision parts. It illsutrates several dfifferent approaches to theis intricate field by taking the reader through the 'hos' and 'whys' of product analysis, as well as the technqiues for blanking, punching, bending, deep drawing, stretching, material economy, strip design, movement of metal duting stamping, and tooling.