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manpro study notes for exam, Lecture notes of Engineering

Thapar Institute of Engineering and TechnologyEngineering

these are my class provded notes to study for my engineering subject manufacturing processes in 1st year

Typology: Lecture notes

2025/2026

Uploaded on 05/08/2026

jasjeet-singh-5
jasjeet-singh-5 🇮🇳

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Sheet Metalworking
•Sheet metalworking includes cutting and forming
operations performed on relatively thin sheets of
metal.
•Typical sheet-metal thicknesses are between 0.4
mm and 6mm .
•When thickness exceeds about 6 mm, the stock
is usually referred to as plate rather than sheet.
•The sheet or plate stock used in sheet
metalworking is produced by flat rolling.
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Sheet Metalworking

  • Sheet metalworking includes cutting and forming operations performed on relatively thin sheets of metal.
  • Typical sheet-metal thicknesses are between 0. 4 mm and 6 mm.
  • When thickness exceeds about 6 mm, the stock is usually referred to as plate rather than sheet.
  • The sheet or plate stock used in sheet metalworking is produced by flat rolling.

Sheet Metalworking

  • The most commonly used sheet metal is low carbon steel ( 0. 06 %– 0. 15 % C typical).
  • Its low cost and good formability, combined with sufficient strength for most product applications, make it ideal as a starting material.
  • Sheet-metal processing is usually performed at room temperature (cold working).
  • The exceptions are when the stock is thick, the metal is brittle, or the deformation is significant.

Sheet Metalworking

  • To facilitate mass production, the sheet metal is often presented to the press as long strips or coils.
  • The three major categories of sheet-metal processes are ( 1 ) cutting, ( 2 ) bending, and ( 3 ) drawing.
  • Cutting is used to separate large sheets into smaller pieces, to cut out part perimeters, and to make holes in parts.
  • Bending and drawing are used to form sheet-metal parts into their required shapes

CUTTING OPERATIONS

  • Cutting of sheet metal is accomplished by a shearing action between two sharp cutting edges.
  • The shearing action is depicted in the four stop- action sketches of Figure, in which the upper cutting edge (the punch) sweeps down past a stationary lower cutting edge (the die).
  • As the punch begins to push into the work, plastic deformation occurs in the surfaces of the sheet.

CUTTING OPERATIONS

  • As the punch moves downward, penetration occurs in which the punch compresses the sheet and cuts into the metal.
  • This penetration zone is generally about one-third to half the thickness of the sheet.
  • As the punch continues to travel into the work, fracture is initiated in the work at the two cutting edges.

PUNCH DIE

SHEARING

  • Shearing is a sheet-metal cutting operation along a straight line between two cut tiny edges, as shown in Figure.
  • Shearing is typically used to cut large sheets into smaller sections for subsequent pressworking operations.
  • It is performed on a machine called a power shears , or squaring shears.
  • The upper blade of the power shears is often inclined, to reduce the required cutting force. 10

SHEARING

PUNCH DIE

Blanking

Useful Part (Blank) (Scrap)

PUNCH DIE

Blanking

Size c db - 2c c (d b ) (dp )

Punching/ Piercing

  • Punching/Piercing is similar to blanking except that it produces a hole, and the separated piece is scrap, called the slug.
  • The remaining stock is the desired part.

PUNCH DIE

Punching/

Piercing

Useful Part Slug (Scrap)

PUNCH DIE 50 + 4 2 50 2

Punching/

Piercing

Clearance

  • The clearance “ c ” in a shearing operation is the distance between the punch and die.
  • Typical clearances in conventional pressworking range between 4 % to 8 % of the sheet-metal thickness t.

c = a(t)

Where a = Allowance = 4 to 8% (1)