MecE265 > Week 5 > Flashcards

Week 5 Flashcards

(49 cards)

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1
Q

what characterizes sheet metal parts

A

constant stock thickness

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2
Q

the two stages of fabrication process for sheet metal

A
  1. forming processes
  2. bending processes
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3
Q

forming process vs. bending process

A

forming processes are performed while the metal is flat

bending process create 3D volume

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4
Q

6 types of forming processes

A
  • shearing
  • slitting
  • punching
  • blanking
  • stamping
  • embossing
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5
Q

what do forming processes often utilize

A

punches and dies to remove material or create indentations

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6
Q

why is stamping notable

A

deforms sheet metal between a cavity and a closly fitting plunger

this BOTH shears and deforms the material to produce complex 3D features.

Successive stamping operations can create highly detailed parts

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7
Q

Bends significance

A

primary means of creating 3D shapes

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8
Q

5 types of bends

A
  1. v bend
  2. edge bends
  3. channel bends
  4. u bends
  5. offset bends
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9
Q

how are v-bends created

A

using a V-shaped punch and die

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10
Q

how are edge bends created

A

a wiping die (bend it down over the edge of the table type shit)

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11
Q

hems

A

used to roll over the edge of a part to smooth a sharp corner or increase stiffness

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12
Q

seams

A

used to join sheet metal parts. can either be left as bent or reinforced through welding or riveting

(think of hooked fingers, of a fancy women toddling towards you or s-shape interlocking fold)

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13
Q

Standard vs sheet model CAD

A

standard: uses boss-extrusions or revolves
sheet metal: all material maintains a uniform material gage

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14
Q

design intent behind using SolidWorks to model sheet metal + and why can CAD do it

A
  • the ability to unfold the part
  • SolidWorks is parametric and feature-based
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15
Q

Standard modeling vs. sheet modeling focus

A
  • standard: final form
  • Sheet metal: manufacturing path, specifically the flat patter
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16
Q

what kind of file are sheet metal parts stored in

A

.sldprt

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17
Q

2 unique feature folders of sheet metal and what they contain

A
  1. “Sheet-Metal” folder stores default thickness and bend radius
  2. “Flat-Pattern” folder manages the unfolded state
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18
Q

3 Specialized features of sheet metal and what they do

A
  1. sheet metal: placeholder for global settings like thickness
  2. base flange: the initial feature that establishes the material gage
  3. flat pattern: stays suppressed while modeling the 3D shape bu can be toggled to show the 2D blank
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19
Q

Neutral plane + why do we define it

A

theoretical area within the thickness where no stretching or compression occurs

when metal is bent, the outer surface stretches and the inner surface compresses. if we draw a line between these two forces, that is the neutral plane

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20
Q

K-factor

Study These Flashcards
A

ratio of the distance from (the inside bend surface to the neutral plane) to the (thickness of the material)

21
Q

common k-factor ratio range

22
Q

Explain what a k-factor of 0.5 means

Study These Flashcards
A

the neutral plane is exactly in the middle of the sheet (the compression and tension on the bend radius are equal)

23
Q

Two methods to calculate the toal length of a flat blank (developed length)

Study These Flashcards
A
  1. bend allowance
  2. Bend Deduction
24
Q

developed length + alternative name

Study These Flashcards
A

total flat length required to form a part (have to account for bends stretching and compressing the material)

flat blank

25
Bend Allowance (BA)
the arc length of the neutral plane through the bend region
26
Bend Deduction (BD)
used in the equation for developed length. (calculation to figure out what size the flat piece of metal needs to be before you bend it, so that after bending you have the correct overall dimensions)
27
sharp apex
the theoretical intersection point of two flat faces if the bend had zero radius
28
when performing bend deduction, where do you measure the flange lengths to
sharp apex
29
equation for bend length using bend deduction + explain
Developed length = side 1 + side 2 - Bend Deduction side 1: one side of the bend side 2: other side of the bend (these will be connected at that sharp apex) Bend Deduction: variable to account for the fact that sheet metal is compressed and stretched during bending.
30
2 distinct workflows for sheet metal + which is recommended
1. base flange method 2. generic model (insert bends) method Base Flange Method is recommended
31
base flange method
builds sheet metal from scratch using dedicated tools
32
3 dedicated tools used in base flange method
1. base flange/tab 2. edge flange 3. miter flange
33
Base flange/tab tool + how does having an open vs. closed part affect the result
starts the sheet metal part Open: results in a thin extrusion along that line such that you begin your design with folds of the set sheet metal thickness Closed: results in a flat sheet of sheet metal, in the shape of the drawing
34
edge flange tool
adds a flange to a selected edge at a specific angle and length
35
miter flange
adds a complex, multi-segment flange to one or more edges, automaticall creating miters in corners
36
miter
a joint formed by cutting two pieces of material at a 45 degree angle to create a 90 degree corner
37
The generic Model (insert bends) method + when is it used
method is used to convert standard solid models into sheet metal complex shaped or imported geometry
38
3 Components of The generic Model (insert bends) method + definition
1. modeling a solid: create the part using standard extrudes and shell features 2. ripe feature: used to break corners so a part can unfold 3. insert bends: converts the sharp corners of the solid into radius bends and establishes the flat pattern
39
shell feature
creates a thin-walled, hollow part from solid bodies
40
3 types of auto relief cuts + describe
1. rectangular: rectangle slots perpendicular to bend line 2. tear: material is naturall allowed to rip apart 3. obround: rectangular slots with a rounded inside. (super skinny arc, white straight sides)
41
auto relief cuts purpose
(think of the little notches beside your bends on solidworks) there is a lot of force of the metal when it is bent and it is at risk of tearing off from the shear stress. By adding relief cuts, you reduce this chance
42
What does a developed drawing of a sheet metal part show + why + what must it have
the part in its flattened state for CNC programming of laser or waterject cutters bend line
43
what does a bend line mark and what is it labelled
the center of the bend CLB (center line of bend)
44
What do bend lines specify
Bend direction: BUP (bent up) or BDN (Bent down) Bend angle: the angle through which the part is bent Inner radius: the radius of the tool used for the bend
45
4 biggest points from the sheet metal unit
1. the constant thickness rule 2. the bend region 3. associativity 4. design for manufacturing (DFM)
46
the constant thickness rule
all features must share the same material guage. if different thicknesses are needed, the part must be modeled as an assembly of multiple sheet metal parts
47
the bend region (from sheet metal summar page)
the reason for k-factor and bend allowance parameters if that the material is physically displaced during bending
48
associativity
in solidworks, the 3D formed part and the 2D flat pattern are associative. ie. changing the flange length in 3D automatically updates the blank size in the flat pattern feature
49
Design for manufacturing (DFM)
small relief cuts and generous bend radii ensure that the part can be manufactured without failing or requiring expensive custom tooling
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