Basics of Sheet metal design for Mechanical design engineers

Course Curriculum

Chapter 1: Introduction

Lecture 1: Introduction to the course

Lecture 2: Design to Production Cycle

Lecture 3: Why Sheet metal?

Lecture 4: Why Knowledge of Process is important for Designer?

Lecture 5: Knowledge and Skills required to Design effectively

Chapter 2: Materials

Lecture 1: Sheet metal Rolling

Lecture 2: Material Selection

Lecture 3: Material Properties

Lecture 4: Steel vs Aluminum

Lecture 5: Modulus

Lecture 6: Hardness

Lecture 7: Toughness and Strength

Lecture 8: Comparison between Hardness, Toughness and Strength

Chapter 3: Common Processes

Lecture 1: Shearing Operation

Lecture 2: Common Processes

Lecture 3: Basic Stamping Process

Lecture 4: Scrap in Sheet metal and Shaving Operation

Lecture 5: Cutting Operations

Lecture 6: Punching Force calculation

Chapter 4: Theory of Plastic Deformation

Lecture 1: What is Plastic Deformation?

Lecture 2: Stress- Strain Curve

Lecture 3: Plastic Elongation in Testing

Lecture 4: Anisotropy

Lecture 5: Grain Size

Chapter 5: Formability

Lecture 1: Introduction to Formability

Lecture 2: Formability Test

Lecture 3: Forming Limit Diagram

Lecture 4: Design Verification using Forming limit diagram – process

Lecture 5: Thinning as a measure of formability

Chapter 6: Bending

Lecture 1: Bending Process

Lecture 2: Bend Parameters and Bend allowance

Lecture 3: Neutral Axis in Bending and K factor

Lecture 4: Bend allowance calculation

Lecture 5: Outside Setback and Inside Setback

Lecture 6: Bend Deduction

Lecture 7: Example Problem 1 – Calculating Blank length

Lecture 8: Relation between Bend arc angle and Flange angle

Lecture 9: Material Effects in Bending

Lecture 10: Minimum Bend Radius

Lecture 11: Tensile Reduction of Area

Lecture 12: Factors that Affect Bendability

Lecture 13: Factors that Affect Bendability – Material Inclusions

Lecture 14: Bending Force Calculation

Lecture 15: Types of Flanging

Lecture 16: Beading operation

Chapter 7: Springback and Wrinkling

Lecture 1: Spring-back and Effects

Lecture 2: Springback Calculation

Lecture 3: Negative Springback

Lecture 4: Counter-acting Springback

Lecture 5: Wrinkling in Sheet metal

Chapter 8: Deep Drawing

Lecture 1: Deep Drawing Operation

Lecture 2: Deep drawing Details

Lecture 3: Deep drawing Practice

Lecture 4: Deep Drawing Force and Drawability

Lecture 5: Ironing and Redrawing

Chapter 9: Other Operations

Lecture 1: Hydroforming

Lecture 2: Tube Hydroforming

Lecture 3: Hydroforming – Why is it used in Automotive and Drawbacks

Lecture 4: Spinning

Lecture 5: Stretch Forming

Lecture 6: Tube Bending

Lecture 7: Roll Forming

Lecture 8: Embossing and Coining

Chapter 10: Sheet metal Joining

Lecture 1: Welding

Lecture 2: Fasteners

Lecture 3: Fasteners vs Welding

Chapter 11: Tools and Equipment

Lecture 1: Simple and Compound Dies

Lecture 2: Progressive Dies

Lecture 3: Transfer Dies

Lecture 4: Press Selection and Design aspects

Lecture 5: Economics of Sheet metal Processing

Chapter 12: Design Considerations

Lecture 1: Manufacturing Cost

Lecture 2: Blank Design

Lecture 3: Bend and Grain Direction

Lecture 4: Stress Concentration

Lecture 5: Design Guidelines for Holes and Tabs

Lecture 6: Design Guidelines for Bend relief 1

Lecture 7: Design Guidelines for Bend relief 2

Lecture 8: Design Guidelines for Flange near Bends

Lecture 9: Design Guidelines for holes near Bends and edges

Lecture 10: Corner Finishing

Lecture 11: Notches of Stretch Flange

Lecture 12: Tooling Holes

Lecture 13: Avoiding Deep channels in Bending

Lecture 14: Tolerance in Sheet metal and Factors

Lecture 15: Beads and Dimples to increase Stiffness

Lecture 16: Alignment of Holes in Bent parts

Lecture 17: Non-formable parts