PRDE 1200 - Theory of Sheet Metal Fabrication

Credit Hours: 3.00

Objectives: The student will:

1. Name three operations used for shaping sheet metal into finished products with 100% accuracy.
2. Define the theory of cutting sheet materials with dies with 100% accuracy, and correctly name four types of forces used for cutting sheet metal.
3. Describe shear force, shear force spacing, and how shear force spacing is determined.
4. Define the following terms with 100% accuracy:
   1. Rollover.
   2. Burnish.
   3. Fracture.
   4. Burr.
5. Describe how penetration is determined and identify whether or not soft metals require more or less penetration to fracture, with 100% accuracy.
6. Define clearance variation with 100% accuracy and describe one appropriate reason that it is an important consideration.
7. Define spacing distortion, secondary shear, dish distortion, shear strength with 100% accuracy, and correctly describe why each occurs.
8. Define wear and shear, and identify where each most usually occur.
9. Define stripping force and list a minimum of two general rules for stripping force.
10. Match each of the following cutting operations: shearing, cutoff, notching, semi-notching, blanking, slitting, punching, parting, perforating, lancing, parting, cutoff, trimming, shaving, and slotting with one of the following categories: producing blanks, cutting holes, progressive working, size control with an accuracy of 100%.

Outcome 2: Upon completion of this course, students will identify sheet metal forming operations.

Objectives: The student will:

1. Describe bending, neutral axis, and the reason a pad is used during bending with 100% accuracy.
2. Identify which radius surface (inside or outside) is held to a closer tolerance when bending, and briefly summarize why with 100 % accuracy.
3. Define springback and name three methods used to minimize springback.
4. Define the following bending operations: bending, flanging, hemming, seaming, curling, and corrugating, with 100% accuracy.
5. Describe at least one way that embossing is different from the forming operations: flanging, curling, and hemming, with an accuracy of 100%.
6. Define bead and rib and one reason why they are used.
7. Define oilcanning, with 100% accuracy.
8. Describe why offsetting is used in 50 words or less.
9. In 50 words or less correctly describe why cold working a concern during the embossing process.
10. Name the two types of embossing die, and briefly describe one difference between each one, with 100% accuracy.
11. Name the term used for operations that cannot be classified in any of the embossing applications.

Outcome 3: Upon completion of this course, students will identify sheet metal drawing operations.

Objectives: The student will:

1. Describe how the term drawing gets its name.
2. List the stages of drawing from initial contact through completion, with 100% accuracy.
3. Name two types of friction that are developed during the drawing process and describe each one in 100 words or less.
4. Identify which part of the cup transmits the punch force to the areas of bending, straightening, friction and compression during the cup drawing process with 100% accuracy.
5. Name the correct cup draw operation used to form a cup bottom that is other than flat.
6. Define “design of experiment”. Correctly describe why it is used in the die profession, and correctly name three draw issues for consideration during the design of experiment.
7. Name and describe two types of redraws and when is the redrawing process used.
8. Describe when box shaped draws are used.
9. Identify whether or not tearing and wrinkling are an issue during box draws.
10. Calculate how much of one corner in a box draw is equivalent to how much of a cup draw, with 100% accuracy.
11. Choose which is apt to wrinkle more easily, thin or thick sheet metal.
12. Describe when beads are used during drawing with 100% accuracy.
13. Define stretch bending and stretch forming.

Outcome 4: Upon completion of this course, students will describe how dies are constructed.

Objectives: The student will:

1. Describe two ways that dies are classified.
2. Determine whether or not a die may perform multiple operations, even though it may be classified by one particular way.
3. Name the classification for each of the following dies with 100% accuracy:
   1. Cutoff die.
   2. Drop through die.
   3. Compound blank and punch die.
   4. Return type die.
   5. Compound die.
   6. Compound blank and draw die.
   7. Combination die.
   8. Continental die.
   9. Compound punch and form die.
   10. Sub-press die.
   11. Follow die.
   12. Drop through blanking die.
   13. Progressive die.
   14. Return-type punch and flange die.
   15. Transfer die.
   16. Sub-press punching die.
   17. Shuttle die.
4. Name two cutting operations that a Cutoff die would be used for, with 100% accuracy.
5. Describe what it means when a die is called drop through.
6. Define the following dies:
   1. Return-type die.
   2. Compound die.
   3. Combination die.
   4. Continental die.
   5. Sub-press die.
   6. Progressive die.
   7. Transfer die.
   8. Shuttle die.

Outcome 5: Upon completion of this course, students will identify the basic construction procedures for dies.

Objectives: The student will:

1. Determine if die terminology is consistent throughout industry the die industry.
2. List what part of the assembly or package of metal components that is place in a press to shape sheet metal is called the die.
3. Determine whether or not dies may be noncomplex for small lot processing, or extremely complex assemblies that will not use transfer devices.
4. Name four die components included the die set, with 100% accuracy.
5. Name the upper and lower die half and describe where each is attached in the press.
6. Define the term die set and describe what would happen if a die set were not used.
7. Define the following terms:
   1. Die steel.
   2. Punch steel.
   3. Stripper plate.
   4. Die spring.
   5. Keeper.
   6. Knockout plate.
   7. Hold down plate.
   8. Pad plate.
   9. Blankholder.
   10. Pressure pin.
   11. Key, dowel.
   12. Heel.
   13. Stop block.
   14. Bolster plate.
   15. Backing plate.
   16. Pilot.
   17. Gage.
   18. Insert.
8. Describe a minimum of one way that cams, hinges, and rockers are used.
9. Describe why a die is not constructed as a welded assembly, or machined from solid.

Outcome 6: Upon completion of this course, students will identify the basic operation of mechanical and hydraulic presses.

Objectives: The student will:

1. Determine whether or not an understanding of basic press operation a necessity during the die design process and describe why.
2. Define each of the following terms:
   1. Frame.
   2. Frame position.
   3. Action.
   4. Drive.
   5. Suspension.
   6. Energy.
   7. Torque.
   8. Tonnage.
   9. Stroke.
   10. Shut height.
   11. Adjustment.
   12. Strokes per minute.
   13. Die space.
   14. Gibbing.
   15. Flywheel.
   16. Die energy.
   17. Clutch.
3. List the number of connecting rods and crankshaft throws for the following types of press suspensions, with 100% accuracy:
   1. One point.
   2. Two point.
   3. Three point.
   4. Four point.

Outcome 7: Upon completion of this course, students will identify various material handling devices used in the stamping industry.

Objectives: The student will:

1. List 4 groups by classification of function for mechanical handling devices, with 100% accuracy.
2. Define the term “Hitch Feed”, with 100% accuracy.
3. Describe the basic operation for each of the following feeding mechanisms for individual parts:
   1. Hopper.
   2. Dial.
   3. Chutes.
   4. Slides.
   5. Magazine.
   6. Step.
   7. Special.
4. Write a correct explanation of each ejection mechanism listed below:
   1. Gravity.
   2. Air.
   3. Kicker.
   4. Litter.
   5. Shovel.
   6. Mechanical hand.
   7. Ejection by next part.
5. What is the purpose of a transfer mechanism?
6. Define each of the following transfer mechanisms:
   1. Conveyor.
   2. Shuttle.
   3. Turnover.
   4. Turnaround.
   5. Stacker.
   6. Rails.

Outcome 8: Upon completion of this course, students will identify the considerations involved in the processing of sheet metal parts.

Objectives: The student will:

1. Define the following terms with 100% accuracy:
   1. Reel.
   2. Cradle.
   3. Stock layout.
   4. Scrap percentage.
   5. Percent utilization.
   6. Spacing.
   7. Progression.
2. List a minimum of two correct considerations to be taken into account when using Strip Stock and Coil Stock in presswork.
3. Describe Direction of Fiber, and Direction of Burr.
4. List a minimum of three factors to consider during press selection that affect press-working performance.
5. Define the following terms with 100% accuracy as they apply to presswork:
   1. Critical dimensions.
   2. Close tolerance.
   3. Baseline.
   4. Special dimensions.
   5. Geometric control.
   6. Mechanical control.
   7. Critical operations.
   8. Non-critical operations.
   9. Tie in operations.
   10. Allied operations.
   11. Inspection operations.
   12. Operations required.
   13. Sequence of operations.
   14. Systems location.
   15. Supports.
6. Describe a minimum of two reasons why the proper selection of equipment important.
7. Define the following major press considerations, with 100% accuracy:
   1. Tonnage.
   2. Speed or strokes per minute.
   3. Bed area.
   4. Shut height.
   5. Stroke.
   6. Number of presses required.
8. Describe with 100% accuracy:
   1. Operation routing (tool routing).
   2. Purchase order.
   3. An engineering change.
   4. Follow up.
9. List a minimum of two basic factors to be considered when cost estimating, with 100% accuracy.
10. With 100% accuracy, define the following:
    1. Styling plaster.
    2. Differential surface area.
    3. Flow control.
    4. Tipping of the styling plaster.
    5. Rubber skin for trim line development.
    6. Plussing of flange breaklines.
    7. Wrap development.
    8. Draw bars for uniform metal flow.
11. Summarize the advantages of using the experimental die.
12. Name two categories of sheet metal uses, with 100% accuracy.

1. Course Orientation
2. Introduction -Theory of Cutting Sheet Metal

Session 2

1. Theory of Cutting Sheet Metal
2. Forces for Cutting
3. Classifications of Cutting Operations

Session 3

1. Forming Operations
2. Bending
3. Embossing

Session 4

1. Assessment Measure 1

Session 5

1. Review Test 1 Answers
2. Drawing Operations
   1. Cup drawing
   2. Box-shapes

Session 6

1. Die Construction Materials
2. Construction Procedures

Session 7

1. Die Construction & Procedures

Session 8

1. Assessment Measure 2

Session 9

1. Review Test 2 Answers
2. Press Operation

Session 10

1. Press Operation

Session 11

1. Assessment Measure 3

Session 12

1. Review Test 3 Answers
2. Handling Devices

Session 13

1. Sheet Metal Processing Considerations

Session 14

1. Sheet Metal Processing Considerations

Session 15

1. Assessment Measure 4

Session 16

1. Review Test 4 Answers
2. Course Evaluation