SHEET METAL WORKING
MECHANICAL ENGINEERING
NEEL METAL PRODUCTS LIMITED
PLOT NO.-5, SEC-36, PACE CITY GURGAON
MAHARSHI DAYANAND UNIVERSITY, ROHTAK
FEBRUARY-2015 TO MAY-2015SUBMITTED TO: SUBMITTED BY:
Mr. K.C.YADAV AJAY SINGH
MECHANICAL DEPARTMENT 011-ME-305
GURGAON INSTITUTE OF TECHNOLOGY & MANAGEMENT
Bilaspur-Tauru Road, NH8, Gurgaon-122413 (Haryana)
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TABLE OF CONTENTS
1. Preface…………………………………………………..…………32. Acknowledgements……………………………………..…………43. Introduction to The Company………………………….
………………………………...51. Company Profile…………………………………………………………………….62. Product Range……………………………………………………………………….73. Customers…………………………………………………………………………...84. Mission………………………………………………………………………………95. Vision………………………………………………………………………………..96. JBM’s Quality
Goals………………………………………………………………...........................9
4. Sheet metal working……………………………………………….10
1. Introduction2. Sheet metal processing3. Processes
5. Type of Press……………………………………………………………………….11
6. Dies and punches………………….……………………………………13
7. Classification of press tools………………………………………14
8. Different types of operations in press shop……………………….18
9. Various sheet metal defects……………………………………….…22
10.Types of testing………………………………………………………………..………….27
11.Conclusion…………………………………………………………….….…..….29
12.References……………………………………………………………………….………….30
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PREFACE
“If one has to succeed in life, one has to keep pace with changing times” this saying
holds good in every field of life be it general or professional. Being the student of the
professional courses we have to keep a constant vigil on rapidly changing environments.
Is Indian industry a protected one? Except some strategically important industries, every
field is thrown to global competition, liberalization and globalization combined with the
privatization of existing public sector companies is the new mantra of Indian economic
policies. So in this era of tough competition only fittest will survive. Industries spend a
lot of capital in making the best out of the availability and improving the present
scenario every time.
With the purpose of getting ourselves abreast with the new trends in improvement
management we went for six months implant training at “NEEL METAL PRODUCT
LIMITED (JBM GROUP)”. On the basis of what we have learnt in the company we are
here by submitting a report.
AJAY SINGH
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ACKNOWLEDGEMENTS
The “adage no man in an island” is certainly true when applied to the successful
completion of any woe work. Here we would like to take a moment to recognize all
those contributed greatly to this effort.
Our sincere regard and heartiest and thanks to our guide MR. SANTOSH YADAV for
their indispensable contribution, inexhaustible patience to deal with our endless queries
and dedication throughout the project without which it would not have been possible for
us to complete the project in the stipulated time .
Special thanks to our other members of organization.
Mr. Santosh Yadav (Quality Department)
We are very thankful to all these people for the kind of support and guidance they
provided us during the entire time period of our internship at the organization.
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INTRODUCTION TO THE COMPANY
JBM is a multi-unit, multi-product group with extensive and diversified interests in
engineering and precision tooling, dies and chemicals and textiles and facilities spread
over different parts of the country. The JBM engineering groups deals in a broad range
of sheets metal assemblies, die casting components and forging for the domestic and the
export market. Jay Bharat Maruti Limited, set up in 1987, is the largest joint venture
of Maruti Udyog Limited, in collaboration with Suzuki Motor Corporation of Japan.
This is unique combination of modern press shop and weld shop of supplying
components in JIT (Just in Time) meeting customer requirements. Manufacturing
facilities at JBML includes die maintenance, dedicated facilities for manufacturing
exhaust system, in-house modern tool room and a talented design team. JBML is rising
to meet new challenges with modern equipment and higher goals of manufacturing and
quality control.
The working environment at JBML is based on Japanese systems of manufacturing. 300
trained and highly motivated personnel are the company’s greatest asset. The core group
works closely with its staff and workers to provide solution and create new goals for
JBML.
With the establishments of JBM Tools Ltd, a joint venture with Tata’s and a number of
other units spread across the country, today JBM is front ranking entity in auto
components. JBM has the resources, expertise and infrastructure to manufacturer a
range of products such as sheet metal stampings, welded sub-assemblies, chassis and
suspension systems and jigs and fixtures.
Since its establishment the group has expanded itself in a big corporate sector. Some of
its companies are JBML-1 Gurgaon, JBML-II Gurgaon, NMPL Gurgaon, JBM-A
Faridabad, JBES Faridabad.
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COMPANY PROFIILE
Jay Bharat Maruti Limited, set up in 1987, is a joint venture of Maruti Udyog Limited
(MUL) with about Rs.1136 Million fixed assets. The plant is equipped with state of the
art technology, in Metal Forming and Welding. The plants are unique combination of
modern Press Shop and Weld Shop capable of supplying components meeting
customer’s quality and quantity requirements.
The company is producing varied range of Sheet Metal components and Welded Sub-
assemblies such as; Front Under Bodies, Rear Under Bodies, Member Assembly Rear
Floor, Fender Assembly and exhaust system for various models of Maruti Udyog
Limited; all Cabin Skin Panels for LCV of Eicher Motor Limited; Front grill for HCV
of TELCO; Longitudinal Members, Cross Members, Floor Panels and Wheel Housings
for JBM Auto Component Limited; Engine Hood for Farm Track Tractors of Escorts
Limited, Front Dome for Greaves Limited, Exhaust Systems, Parts for Delphi
Automotive Systems Limited and Mufflers for Honda
Motors & Scooter India Ltd.
Established in 2001, Neel Metal Products Ltd. (NMPL) is the fastest growing Company
of JBM Group with high-tech plants at various locations in India. NMPL has earned a
leading position in industry with facilities available in press lines up to 1200 tons, weld
lines and ED coating plant-
include: Mechanical and hydraulic press line up to1000 tones.
Automatic Tandem Press line with lead press of 800 tones.
Five axis Laser cutting machines.
Standard and Special Purpose Stationary/Portable, MIG/MAG/Resistance/MIG Welding machines.
Six axis articulated type Arc welding robots.
CNC pipe bending machines.
Special Purpose Machines for manufacturing of Exhaust systems.
Hydraulic Die Spotting Press of 50 tones.
All conventional tool room machines.
Computerized 3D coordinate measuring machine.
Panel checkers, inspection gauges and meteorological equipment. Semi-automatic paint shops for mufflers.
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PRODUCT RANGE
JBML is manufacturing different components for various customers.
The product range of the firm is:
Complete body assemblies and painting facilities for 3 and 4 Wheelers.
Complete Frame Assembly, welding and painting for 2 Wheelers.
Design, Development and manufacturing of precision tooling, dies and welding
fixtures for automotive use.
Exhaust manufacturing and painting for 2 wheelers.
Fuel Tank manufacturing for 2 wheelers.
Manufacturing of Rims and Wheel Assemblies for 2 Wheelers.
Manufacturing of ERW and CDW Tubes for Tubular Components.
CUSTOMERS
CARS/MUV Ford India General Motors Hindustan Motors Honda Steel Maruti Udyog Limited Toyota Kirloskar
TRACTORS Eicher Escorts HMT L&T John Deere M&M Tafe International Tractors New Holland
HCV/LCV Ashok Leyland Eicher Motor Mahindra and Mahindra Volvo
TWO/THREE WHEELERS Yamaha Motors India Plaggio India TVS Suzuki
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Honda Motorcycle
MISSION
“To make JBML a synonym for world class organization excelling in sheet metal technologies”
VISION
“Expending leadership in our business through people keeping pace with market trend
and technology”
JBM’S QUALITY GOALS Zero Defects
First Time Right, Every Time Right
No Quality Control, Only Quality Assurance
Reduced Process Variance
100% Customer Satisfaction
Reduction in The Cost of The Product
SHEET METAL WORKING
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IntroductionSheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental
forms used in metalworking, and can be cut and bent into a variety of different shapes.
Countless everyday objects are constructed of the material. Thicknesses can vary
significantly, although extremely thin thicknesses are considered foil or leaf, and pieces
thicker than 6 mm (0.25 in) are considered plate.
Sheet metal processing The raw material for sheet metal manufacturing processes is the output of the rolling
process. Typically, sheets of metal are sold as flat, rectangular sheets of standard size. If
the sheets are thin and very long, they may be in the form of rolls. Therefore the first
step in any sheet metal process is to cut the correct shape and sized ‘blank’ from larger
sheet.
1. Sheet metal processes involve plane stress loadings and lower forces than
bulk forming
2. Almost all sheet metal forming is considered to be secondary processing
3. The main categories of sheet metal forming are
• Shearing
• Bending
• Drawing
ShearingShearing is a sheet metal cutting operation along a straight line between two cut-ting
edges
by means of a power shear.
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Blanking and punching
Blanking and punching is similar sheet metal cutting operations that involve
cutting the sheet metal along a closed outline. If the part that is cut out is the desired
product, the operation is called blanking and the product is called blank. If the
remaining stock is the desired part, the operation is called punching. Both operations are
illustrated on the example of producing a washer
BendingBending is defined as the straining of the sheet metal around a straight edge
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Types of press
Mechanical Press
The ram is actuated using a flywheel. Stroke motion is not uniform.
Mechanical punch presses fall into two distinct types, depending on the type of clutch or
braking system with which they are equipped. Generally older presses are "full
revolution" presses that require a full revolution of the crankshaft for them to come to a
stop. This is because the braking mechanism depends on a set of raised keys or "dogs"
to fall into matching slots to stop the ram. A full revolution clutch can only bring the
ram to a stop at the same location- top dead center. Newer presses are often "part
revolution" presses equipped with braking systems identical to the brakes on
commercial trucks. When air is applied, a band-type brake expands and allows the
crankshaft to revolve. When the stopping mechanism is applied the air is bled, causing
the clutch to open and the braking system to close, stopping the ram in any part of its
rotation.
Hydraulic Press 11
Longer strokes than mechanical presses, and develop full force throughout the stroke.
Stroke motion is of uniform speed, especially adapted to deep drawing operations
Hydraulic punch presses, which power the ram with a hydraulic cylinder rather than a
flywheel, and are either valve controlled or valve and feedback controlled. Valve
controlled machines usually allow a one stroke operation allowing the ram to stroke up
and down when commanded. Controlled feedback systems allow the ram to be
proportionally controlled to within fixed points as commanded. This allows greater
control over the stroke of the ram, and increases punching rates as the ram no longer has
to complete the traditional full stroke up and down but can operate within a very short
window of stroke.
Dies and Punches
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A die is a specialized tool used in manufacturing industries to cut or shape material
mostly using a press. Like molds, dies are generally customized to the item they are
used to create. Products made with dies range from simple paper clips to complex
pieces used in advanced technology.
Die components
The main components for die tool sets are:
Die block - This is the main part that all the other parts are attached to.
Punch plate - This part holds and supports the different punches in place.
Blank punch - This part along with the blank die produces the blanked part.
Pierce punch - This part along with the pierce die removes parts from the
blanked finished part.
Stripper plate - This is used to hold the material down on the blank/pierce die
and strip the material off the punches.
Pilot - This is used to keep the material being worked on in position.
Guide, back gauge, or finger stop - These parts are all used to make sure that the
material being worked on always goes in the same position, within the die, as the
last one.
Setting (stop) block - This part is used to control the depth that the punch goes
into the die.
Blanking dies - See blanking punch
Pierce die - See pierce punch.
Shank - used to hold in the presses. it should be aligned and situated at the center
of gravity of the plate.
Classification of press tools
Blanking tool
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Blanking Tool
When a component is produced with one single punch and die where the entire
outer profile is cut in a single stroke the tool is called a blanking tool.
Blanking is the operation of cutting flat shapes from sheet metal.
The outer area of metal remaining after a blanking operation is generally
discarded as waste.
Size of blank or product is the size of the die & clearance is given on punch.
It is a metal cutting operation.
Piercing Tool
Piercing tool
Piercing involves cutting of clean holes with a resulting scrap slug. The operation is
called die cutting and can also produce flat components where the die, the shaped tool,
is pressed into a sheet material employing a shearing action to cut holes. This method
can be used to cut parts of different sizes and shapes in sheet metal, leather and many
other materials.
Cut off tool
Cutoff tool
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Cut off operations are those in which a strip of suitable width is cut to length in a single
operation. Cut-off tools can produce many parts. The required length of strip can be cut
off for bending and forming operations using this tool.
Parting off tool
Partings are similar, in that a discrete part is cut from a sheet or strip of metal along a
desired geometric path. The difference between a cutoff and a parting is that a cutoff
can be nestled perfectly on the sheet metal, due to its geometry. With cutoffs, the cutting
of sheet metal can be done over one path at a time and there is practically no waste of
material. With partings, the shape can not be nestled precisely. Parting involves cutting
the sheet metal along two paths simultaneously. Partings waste a certain amount of
material, that can be significant.
Trimming tool
When cups and shells are drawn from flat sheet metal the edge is left wavy and
irregular, due to uneven flow of metal. Shown is flanged shell, as well as the trimmed
ring removed from around the edge. While a small amount of Material is removed from
the side of a component in trimming tool.
Trimming Tool
Shaving tool
Shaving removes a small amount of material around the edges of a previously blanked
stampings or piercing. A straight, smooth edge is provided and therefore shaving is
frequently performed on instrument parts, watch and clock parts and the like. Shaving is
accomplished in shaving tools especially designed for the purpose.
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Bending tool
Bending tools apply simple bends to stampings. A simple bend is done in which the line
of the bend is straight. One or more bends may be involved, and bending tools are a
large important class of press tools.
Bending Tool
Forming tool
Forming tools apply more complex forms to work pieces. The line of bend is curved
instead of straight and the metal is subjected to plastic flow or deformation.
Drawing tool
Drawing tools transform flat sheets of metal into cups, shells or other drawn shapes by
subjecting the material to severe plastic deformation. Shown in fig is a rather deep shell
that has been drawn from a flat sheet.
Drawing Tool
This type of Press tool is used to perform only one particular operation therefore
classified under stage tools.
Progressive tool
A progressive tool differs from a stage tool in the following respect: in a progressive
tool the final component is obtained by progressing the sheet metal or strip in more than
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one stage. At each stage the tool will progressively shape the component towards its
final shape, with the final stage normally being cutting-off.
Compound tool
The compound tool differs from progressive and stage tools by the arrangement of the
punch and die. It is an inverted tool where blanking and piercing takes place in a single
stage and also the blanking punch will act as the piercing die.
Combination tool
In a combination tool two or more operations such as bending and trimming will be
performed simultaneously. Two or more operations such as forming, drawing,
extruding, embossing may be combined on the component with various cutting
operations like blanking, piercing, broaching and cut off takes place- it can perform a
cutting and non cutting operations in a single tool.
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Different operations in press shop
Blanking: A blanking die produces a flat piece of material by cutting the desired shape in one operation. The finish part is referred to as a blank. Generally a blanking die may only cut the outside contour of a part, often used for parts with no internal features.Three benefits to die blanking are:
1. Accuracy. A properly sharpened die, with the correct amount of clearance
between the punch and die, will produce a part that holds close dimensional
tolerances in relationship to the parts edges.
2. Appearance. Since the part is blanked in one operation, the finish edges of the
part produces a uniform appearance as opposed to varying degrees of burnishing
from multiple operations.
3. Flatness. Due to the even compression of the blanking process, the end result is a
flat part that may retain a specific level of flatness for additional manufacturing
operations.
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Punching:
Punch tooling (punch and die) is often made of hardened steel or tungsten
carbide. A die is located on the opposite side of the workpiece and supports the
material around the perimeter of the hole and helps to localize the shearing
forces for a cleaner edge. There is a small amount of clearance between the
punch and the die to prevent the punch from sticking in the die and so less force
is needed to make the hole. The amount of clearance needed depends on the
thickness, with thicker materials requiring more clearance, but the clearance is
always less than the thickness of the workpiece. The clearance is also dependent
on the hardness of the workpiece. The punch press forces the punch through a
workpiece, producing a hole that has a diameter equivalent to the punch, or
slightly smaller after the punch is removed. All ductile materials stretch to some
extent during punching which often causes the punch to stick in the workpiece.
In this case, the punch must be physically pulled back out of the hole while the
work is supported from the punch side, and this process is known as stripping.
The hole walls will show burnished area, rollover, and die break and must often
be further processed. The slug from the hole falls through the die into some sort
of container to either dispose of the slug or recycle it.
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Parting:
Parting uses a blade-like cutting tool plunged directly into the workpiece to cut
off the workpiece at a specific length. It is normally used to remove the finished
end of a workpiece from the bar stock that is clamped in the chuck. Other uses
include things such as cutting the head off a bolt.
Perforating:
It is process by which small multiple holes close together are cut in flat work
material.
Trimming:
Punching away excess material from the perimeter of a part, such as trimming
the flange from a drawn cup.
Shaving:
Shearing away minimal material from the edges of a feature or part, using a
small die clearance. Used to improve accuracy or finish. Tolerances of ±0.001
inches are possible.
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Notching - Punching the edge of a sheet, forming a notch in the shape of a portion of the punch.
Drawing: Is a metalworking process which uses tensile forces to stretch metal. As the
metal is drawn (pulled), it stretches thinner, into a desired shape and thickness.
Drawing is classified in two types: sheet metal drawing and wire, bar, and tube
drawing. The specific definition for sheet metal drawing is that it involves
plastic deformation over a curved axis. For wire, bar, and tube drawing the
starting stock is drawn through a die to reduce its diameter and increase its
length. Drawing is usually done at room temperature, thus classified a cold
working process, however it may be performed at elevated temperatures to hot
work large wires, rods or hollow sections in order to reduce forces.
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Various defects in press shop:
Forming Defects
The forming of ingots, or smaller pieces of a larger ingot section, may be carried out by
the forging or hot rolling processes. As noted earlier, defects in billets may be carried
over into later processes where they can pose a potential problem.
defects can be introduced by the forming process, typically restricted to cracks, and
surface shape and size related defects.
Cracks, Laps and Seams
Closed-die forging produces a sliver of material which is forced out between the dies.
This is known as “flash”. The flash is removed after forging, but if the strain
experienced during extrusion of the flash is excessive, the flash may crack. Occasionally
the cracks can run into the forging and remain when the flash has been removed. The
resultant defect is known as a flash crack.
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Figure:Forging bursts and flash cracks
During the reduction of thick section forgings, high levels of triaxial stress can be set up
deep within the sections. If the stress exceeds the tensile strength of the material,
fissures can form. These are referred to as forging bursts. Bursts can be surface
breaking, but are more often wholly embedded and therefore difficult to detect.
Metals that are quite malleable at room temperature such as aluminum, copper and lead,
can be formed either without any additional heat, or with only a modest amount. On the
other hand, metals or alloys that have high temperature strength need to be heated to a
point where they can be forged. This can then lead to oxidation and surface scaling,
which in itself is not necessarily detrimental, but can lead to secondary problems. More
specifically, the surface scale can become folded and rolled into the surface in deep
channels. This then forms a line of weakness if not removed during subsequent
manufacturing operations..
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Being a hot process, the outer surface will be oxidized and during the latter stages, this
oxide is extruded with the metal and enters the extrusion. This effect is
When forging close to the finished product shape,it is clearly important to ensure that
the blank is of adequate size and shape to fill the mold to produce the desired
During direct extrusion, as the billet is forced out through the die, the center sections of
the ingot are extruded first, the outer surface moving to the center as the extrusion
eliminated in indirect extrusion. High–speed or high temperature extrusion can also
result in defects when lubrication becomes difficult. Friction between the product and
component. If the mold is incompletely filled, then some part of the finished product
will be missing. Although this may be obvious during even the simplest of quality
the dies can result in sticking of the product to the die. As the extrusion breaks away,
fissures known as speed cracks are formed.
control checks, many mass produced products are only sample checked at manufacture
and rejectable products may not be detected.
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