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Hydroforming is capable of producing parts within tight tolerances including aircraft tolerances where a common tolerance for sheet metal parts is within 0.76 mm (1/30th of an inch). Metal hydroforming also allows for a smoother finish as draw marks produced by the traditional method of pressing a male and female die together are eliminated.
Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. [1] It is thus a shape transformation process with material retention. The process is considered "deep" drawing when the depth of the drawn part exceeds its diameter.
In the deep drawing process, a blank of sheet metal (usually circular) is placed on the die. The die is fixed to the base. The metal blank is held in position on the die using blank holder. Mechanical force is applied on the part of the metal blank above the die cavity through a punch. As the punch force increases the metal flows from the ...
Today the metal forming industry is making increasing use of simulation to evaluate the performing of dies, processes and blanks prior to building try-out tooling. Finite element analysis (FEA) is the most common method of simulating sheet metal forming operations to determine whether a proposed design will produce parts free of defects such as fracture or wrinkling.
A typical later PSP was the M8 landing mat. A single piece weighed about 66 pounds (30 kg) and was 10 ft (3.0 m) long by 15 in (0.38 m) wide. The hole pattern for the sheet was produced to allow easier transportation by aircraft, since it weighed about two-thirds as much.
Car chassis with lightening holes, circa 1935. Lightening holes became a prominent feature of motor racing in the 1920s and 1930s. Chassis members, suspension components, engine housings and even connecting rods were drilled with a range of holes, of sizes almost as large as the component.
Rubber pad forming process, 1: bottom of the press. 2: lower die. 3: sheet metal. 4: rubber pad. 5: top of the press. Rubber pad forming (RPF) is a metalworking process where sheet metal is pressed between a die and a rubber block, made of polyurethane. Under pressure, the rubber and sheet metal are driven into the die and conform to its shape ...
In sheet metal drawing, as a die forms a shape from a flat sheet of metal (the "blank"), the material is forced to move and conform to the die. The flow of material is controlled through pressure applied to the blank and lubrication applied to the die or the blank. If the form moves too easily, wrinkles will occur in the part.