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Method for metal fabrication

  1. Sep 22, 2015 #1
    • Member warned about posting with no template and with no effort
    Hello, I am a last year mechanical engineer student in Marocco, and i have no idea to solve a problem with my final year project, since we have never studied a thing about Metal fabrication.

    The question is " give one method the Cone Deck could be formed in mass production assuming that flat pattern blanks are already cut.
    With that method, prepare a simple process flow from raw material to finished part.
    I have attached the 'cone deck' picture.

    I need help please, i am lost.

    Attached Files:

  2. jcsd
  3. Sep 22, 2015 #2


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    How big is it and what thickness of what metal ???
  4. Sep 22, 2015 #3


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    So, you study mechanical engineering and you've never taken a course in machine design, drafting, or metallurgy?
  5. Sep 23, 2015 #4
    I do, metallurgy not really, we do study in paper & simulation & drafting using software, like, solidwork, catia, adams,, we don't do stuff really, we don't have needed equipment since it costs a lot.

    I have attached more details about it's thickness and all.

    Thank you very much for your help

    Attached Files:

  6. Sep 23, 2015 #5


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  7. Sep 23, 2015 #6
    Thank you ! :)
  8. Oct 10, 2015 #7

    I have a similar question. I am having difficulty understanding what the raw material would be for this blank provided, and cannot properly understand all the components of the engineering drawing.

    I have created a basic process flow as the prompt instructs, and would like to know if all my portions/steps are sequentially correct and make sense.

    1. Sheering force upon a sheet metal, with a safe clearance distance away from die.
    2. Drawing force punched unto blank held upon die.
    3. Blank force punched into blank at fracture point; sheet metal held upon die.
    I am a Mech Eng. student but haven't taken a materials or manufacturing course yet. However, your help would be immensely appreciated for this prompt. Thanks!
  9. Oct 10, 2015 #8


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    (1) The material is not specified but Aluminium or Mild Steel are commonly used for this sort of component . Most metals used in general engineering can be worked with press tools . Special very ductile grades of metals are available but ordinary general purpose grades are commonly used as well .

    (2) There are two primary processes used in press tools :

    Cutting where metal is removed from the blank - as in punching a hole .
    Forming where metal is distorted - as in pressing flat metal into a bowl shape .

    (3) In the cutting process :

    The bottom part of the tool is a block that has a hole in it of same shape and size as the required cut out in sheet metal blank .
    The top part of the tool is a plunger of same shape and size as hole in block .

    Blank is laid on bottom block and top plunger comes down to cut through the blank and continue a short distance further .
    The cut out piece may drop through the hole in the block or it may have to be ejected by a separate mechanism .

    Block is commonly called a die and plunger is commonly called a punch . The hole in the die is very slightly larger than required cut out and/or punch is very slightly smaller .
    Size difference allows for working clearance but is always kept to an absolute minimum .
    Both punch and die have sharp cutting edges and have to be made from very special steels to withstand what is a very high load and often abrasive process .

    Punch and die have to be kept in exact alignment . This is done by guiding the punch itself or by using slides on the press machine structure .

    Large forces are usually needed for cutting .
    Lubricants are sometimes used .

    (4) In the forming process :

    Actions are similar to cutting but die has a shaped cavity in it and punch has a matching shape but reduced in size all round working faces
    by one thickness of metal being worked .

    Metal blank usually has to be held down firmly all round forming area to prevent unwanted distortions .
    Where possible cavity and tool profile are made smooth and with tapered sides so as to ease flow of metal , to prevent jamming and to ease removal of blank after forming .

    More complex pressed out shapes are sometimes done in stages in sequential punch and die sets .

    (5) Actual press tools as for example used for making car panels often have much more complexity than simple ones described above . There can be multiple moving parts for the cutting and forming and auxiliary moving parts for clamping blank and ejecting both finished part and waste material .

    (6) Design of press tooling for making complex parts can be very difficult . In modern times this is aided by finite element and other modelling methods but traditionally it was done just using skill and experience .

    This is a huge subject and cannot be covered properly in one posting . Please ask any questions you like .
    Last edited: Oct 10, 2015
  10. Oct 10, 2015 #9
    Please explain these processes in more detail:

    - What are the cavity and tool profile?

    - Can you go into more detail for these two steps? What is the most efficient, sustainable, and easiest approach for ejecting waste material?
    - What is a simple process for ejecting the made part?

    I sincerely appreciate your help - truly!
  11. Oct 10, 2015 #10


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  12. Oct 10, 2015 #11


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    Tool profile is shape of punch .
    Cavity profile is shape of hole in die .
    Last edited: Oct 10, 2015
  13. Oct 10, 2015 #12

    - Can you go into more detail for these two steps? What is the most efficient, sustainable, and easiest approach for ejecting waste material?
    - What is a simple process for
    ejecting the made part?
  14. Oct 11, 2015 #13


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    One is asking for a lot of information without knowledge of a specific application, e.g., process volume, as in limited run, short run, large run. One could stamp individual parts or several parts simultaneously depending on the volume.

    Here is some examples - http://www.dekalbtool.com/tool-die-manufacturing-and-design.html

    http://www.dekalbtool.com/deep-drawn-stamping-of-galvanized-steel-bus-roof-cap.html (video).

    Please demonstrate some effort and do one's own research before requesting further information. One may search for "tool and die making/manufacturing".

    Thread will be closed pending moderation.
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