TECHNOLOGY

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Technology

Modern Sheet-Metal Forming Processes Used In the Automotive Industry

The sheet is produced through a laminating process and is subsequently packed in coils of various thickness and width for easy transport. Following are some of the processes for the manufacturing of sheet in automotive industry (Bawa, 2004, pp. 222-225):

Sheet-Metal Forming Processes

As a first approximation, and for simplicity we define shaping operations of those through which the sheet is given the desired contour, with any holes and slots, in order to obtain a plate shape hexagonal perforated, and forming operations those that transform the shaped piece in a three-dimensional object. Both operations take place through a series of processes called cutting, stamping and bending (Gieras & Piech, 2012, pp. 110-115).

The cut is the first operation of the shaping step of sheet. The traditional technique for cutting sheet metal is the shearing. In it, however, are facing newer techniques: flame cutting, plasma cutting, laser cutting and water jet cutting. The cutting operation for shearing is performed by machines called shears. The shears are the most frequent use of guillotine circular blades. In both types, the separation of the parts is produced by the mechanical action of two blades whose effort exceeds the breaking strength of the material (Gieras & Piech, 2012, pp. 110-115).

The Guillotine Shears

The guillotine shears is the most common and consists of two blades, one fixed under the metal sheet and the other, and upper, moved by hydraulic pistons powered by a hydraulic unit. Each machine is equipped with a device called a blank holder, which allows block the material during cutting and by adjustable guides on which is placed the plate (Bawa, 2004, pp. 222-225).

The Shear Blade Circular

The shears with circular blades is constituted by two parallel rotary shafts on which are mounted the circular blades. The sheet, dragged from the disks between the two shafts, is cut into longitudinal direction. Normally this type of shear is used to cut the coil previously levelled, since before it is reduced in sheets (Gieras & Piech, 2012, pp. 110-115).

Oxyfuel

The oxyfuel is the older technique among all those not traditional and uses the heat of a flame produced by a mixture of oxygen and acetylene by means of a torch similar to that used for oxyacetylene welding. The torch is equipped with a drill with a central nozzle from which comes out the oxygen and concentric holes from which exits the acetylene. The flame cutting is mainly used for cutting steels, Also of great thickness. The torch can be used manually or mounted on pantographs (Gieras & Piech, 2012, pp. 110-115).

Plasma Cutting

The work with the plasma using a gas jet (typically a mixture of hydrogen and nitrogen) that, sent in a torch of appropriate structure, is ionized due to the high temperature produced by an electric arc or by the action of a high-frequency inductor. The main characteristics of plasma cutting consist being a very versatile system, so as to be used for various types of materials, including non-ferrous metals; moreover, does not produce ...