The Metal Stamping Process

Includes a complete Excel program for cost estimating tools and parts.

Process Control for Sheet-Metal Stamping presents a comprehensive and structured approach to the design and implementation of controllers for the sheet metal stamping process. The use of process control for sheet-metal stamping greatly reduces defects in deep-drawn parts and can also yield large material savings from reduced scrap. Sheet-metal forming is a complex process and most often characterized by partial differential equations that are numerically solved using finite-element techniques. In this book, twenty years of academic research are reviewed and the resulting technology transitioned to the industrial environment. The sheet-metal stamping process is modeled in a manner suitable for multiple-input multiple-output control system design, with commercially available sensors and actuators. These models are then used to design adaptive controllers and real-time controller implementation is discussed. Finally, experimental results from actual shop floor deployment are presented along with ideas for further improvement of the technology. Process Control for Sheet-Metal Stamping allows the reader to design and implement process controllers in a typical manufacturing environment by retrofitting standard hydraulic or mechanical stamping presses and as such will be of interest to practising engineers working in metal-working, automotive and aeronautical industries. Academic researchers studying improvements in process control and how these affect the industries in which they are applied will also find the text of value.

Companies continue to struggle to maintain, manage and control sheet metal stamping operations in a manufacturing environment, but proven strategies and procedures can turn things around. Author Thomas Ulrich, who has been in the die construction business since 1964, played a leadership role in developing a successful and comprehensive preventive maintenance process for large body-panel stamping dies at Chrysler Corp. In this step-by-step guidebook, he delivers a technical, methods-centric examination of the challenges of maintaining, managing, and controlling sheet metal stamping operations. You'll learn how outsourcing, downsizing, and slashing costs can hurt firms; how to take internal steps to improve existing manufacturing processes to improve performance, sustainability, and the bottom line; and how to apply specific methods to bring sheet metal operations under control, thus allowing profit centers to flourish. This is a practical and functional guide that any company can use to successfully improve its sheet metal tool and die operations. Written in easy to understand and precise prose, it serves as an indispensable resource for managers, comptrollers, production managers, PM coordinators, engineers, and anyone working on the front lines of a sheet metal stamping operations.

Provides an in-depth understanding of the fundamentals of a wide range of state-of-the-art materials manufacturing processes Modern manufacturing is at the core of industrial production from base materials to semi-finished goods and final products. Over the last decade, a variety of innovative methods have been developed that allow for manufacturing processes that are more versatile, less energy-consuming, and more environmentally friendly. This book provides readers with everything they need to know about the many manufacturing processes of today. Presented in three parts, Modern Manufacturing Processes starts by covering advanced manufacturing forming processes such as sheet forming, powder forming, and injection molding. The second part deals with thermal and energy-assisted manufacturing processes, including warm and hot hydrostamping. It also covers high speed forming (electromagnetic, electrohydraulic, and explosive forming). The third part reviews advanced material removal process like advanced grinding, electro-discharge machining, micro milling, and laser machining. It also looks at high speed and hard machining and examines advances in material modeling for manufacturing analysis and simulation. Offers a comprehensive overview of advanced materials manufacturing processes Provides practice-oriented information to help readers find the right manufacturing methods for the intended applications Highly relevant for material scientists and engineers in industry Modern Manufacturing Processes is an ideal book for practitioners and researchers in materials and mechanical engineering.

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.

Descripción del editor: "heet forming fundamentals are thoroughly addressed in this comprehensive reference for the practical and efficient use of sheet forming technologies. The principle variables of sheet forming-including the interactions between variables-are clearly explained, as a basic foundation for the most effective use of computer aided modeling in process and die design.Topics include stress analysis, formability criteria, tooling, and materials for sheet forming. The book also covers the latest developments in sheet metal forming technology, including servo-drive presses and their applications, and advanced cushion systems in mechanical and hydraulic presses." (ASM International).

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

Condition modelling and control is a technique used to enable decision-making in manufacturing processes of interest to researchers and practising engineering. Condition Monitoring and Control for Intelligent Manufacturing will be bought by researchers and graduate students in manufacturing and control and engineering, as well as practising engineers in industries such as automotive and packaging manufacturing.