FASCINATION OF SHEET METAL

A material of limitless possibilities

ABOUT THIS PUBLICATION

This work is protected by copyright. All rights reserved, including the right to translate, reprint, or reproduce this book or any part thereof. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means whatsoever, whether electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. While great care has been taken to ensure the accuracy of the contents of this book, the author, the editor and the publisher do not assume any liability for damages, direct or indirect, arising from the use of this book, in part or total, except where prohibited by law.

Editor Dr. Nicola Leibinger-Kammller, TRUMPF GmbH + Co. KG, Ditzingen, Germany Author Gabriela Buchfink Translation Matthew R. Coleman Project coordinators Frank Neidhart, Gabriela Buchfink Project associates Dr. Nicola Leibinger-Kammller, Dr. Klaus Parey, Ingo Schnaitmann Layout and design Felix Schramm, Karen Neumeister (SANSHINE GmbH, Stuttgart) Text consultant Gurmeet Rcker Translation coordination euroscript Deutschland GmbH, Berlin Production coordination Jeanette Blaum (SANSHINE GmbH, Stuttgart) Printing Rsler Druck GmbH, Schorndorf Finishing Oskar Imberger & Shne GmbH, Stuttgart Binding Josef Spinner Grobuchbinderei GmbH, Ottersweier Image editing Reprotechnik Herzog GmbH, Stuttgart

Publisher Vogel Buchverlag, Wrzburg ISBN-13 978-3-8343-3071-0 ISBN-10 3-8343-3071-X

1st edition 2006

SHEET METAL DISCOVER THE POSSIBILITIES

S H E E T M E TA L D E S I G N I S M O R E T H A N J U S T E N G I N E E R I N G I TS A N A R T. I T M E A N S W O R K I N G C R E AT I V E LY W I T H I N S T R I C T T I M E A N D C O S T R E S T R A I N T S, WHILE FORGING AHEAD IN NEW DIRECT I O N S. P R O V E N S T R AT E G I E S A N D S TAT E - O F-T H E - A R T C O M P U T E R T E C H NOLOGY ARE INDISPENSABLE TOOLS FOR FINDING OPTIMUM SOLUTIONS FOR FA B R I C AT I N G I N C R E A S I N G LY C O M P L E X S H E E T M E TA L PA R T S.
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SHEET METAL DISCOVER THE POSSIBILITIES

THE DAYS OF THE DRAWING BOARD ARE OVER THE SHEET METAL PROCESS CHAIN Putting it all together Creating the finished product step by step Data flow BEFORE DESIGNING BEGINS When to choose sheet metal Strategies for finding new solutions

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MAKING IT WORK Creating functional designs Creating economical designs You designed it. Now can you produce it?

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CREATIVE IN CYBERSPACE

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The days of the drawing board are over

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Designing parts on a drawing board 3D design on a computer Simple sheet metal part Complex sheet metal part

The end of the white coat For a long time, the word design engineer conjured up images of a fussy, narrow-minded perfectionist dressed in a white coat. Because of their outfit, design engineers were sometimes called white coats. Despite their image, design engineers were the same back then as they are today: inventive, creative minds striving to meet a wide range of demands.

SERVING EM UP HOT WITH SHEET METAL What can I get you? Ill have the spaghetti Bolognese. An extra large portion of spaghetti lands with a gentle plop on a preheated plate. The Bolognese sauce is poured over the noodles, and the plate is placed on the table in front of Reinhold Portscheller. The spaghetti isnt the only thing hes happy about. Reinhold Portscheller is a design engineer at Rieber GmbH + Co. KG in Reutlingen, Germany, and knows just how much work went into designing the plate dispenser cart from which his preheated plate just came. The sheet
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metal part used for pushing up the plates used to look very different from the way it does now. The part holding up the plates used to be composed of

There was a time when the most important tools of a design engineer were parchment paper, ink pens, razor blades for erasing mistakes, a drawing board, and stacks of tables listing standardized parts. As a manufacturing material, sheet metal was not as flexible or versatile as it is today. For this reason, parts were often constructed of individual prefabricated standardized components. The last 25 years has seen a complete change in the way design engineers work. Todays manufacturing techniques allow sheet metal to be cut, formed, bent, or joined in almost any way imaginable. In the past, it was common practice to construct a module of many simple parts. Today, design engineers strive to use as few single parts as possible. The parts themselves, however, can be extremely complex. Once an indispensable tool, the drawing board disappeared from engineering firms long ago. Today, design engineers can create 3D sheet metal parts directly at the computer screen. All subsequent steps from unfolding the part all
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the way to machine programming are performed by the computer. Even production can be simulated with the help of special design and programming software. If the software detects any problems, the engineer can make the appropriate changes to the part. Electronic data flow bridges the gap between design, programming, and production. As in the past, design engineers work at the start of a process chain in which they play a key role. An important part of their job is to ensure that processes run smoothly and efficiently.

seven elements with 39 bends and numerous welding spots, recalls Portscheller. Manufacturing the part was extremely complicated. All single parts were manufactured separately, put into temporary storage, and then joined. The spot welding jig alone was, in Portschellers words a real behemoth. No question about it: the sheet metal part was in dire need of some serious production streamlining. Portscheller and his colleagues were delegated the task of improving operation while lowering production costs. With this in mind, the design engineer turned to an out -of -company workshop. This was a good decision, says Portscheller looking back. You had colleagues from other companies and industries all sitting at the same table. We were eager to exchange information, and we approached things in an open -minded way. Instead of simply modifying aspects of the part, the workshop participants started over from scratch. They asked themselves, is this hexagonal form really necessary? Indeed, this
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The plate dispenser is used to hold and dispense heated plates. The plates rest on an optimized sheet metal element.

turned out to be the crucial question. The sheet metal part is now triangular in shape. We reduced seven single parts to two. Also, we now only need seven bends and a few weld spots, says Portscheller with a smile. But thats not all the new solution has to offer. The plates are pushed upwards much more evenly, the part is more attractive than it used to be and our production costs have been slashed considerably, he explains. Portschellers colleagues now require much less time for laser cutting, bending, and spot welding than they did before. Plus, they no longer have to put the single parts into temporary storage. This saves both time and space. A success story? It sure is, confirms the design engineer and finally turns his attention to his lunch.

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The sheet metal process chain

PUTTING IT ALL TOGETHER From the idea to the finished part to put it in a nutshell, thats what the sheet metal process chain is all about. The companys goal is to manufacture high-grade parts in a way that is both fast and cost effective. For this to happen, individual stages of the process have to be coordinated as precisely as possible. Coordination begins at the design stage. For example, if the engineer decides to create a part that will have round punch holes, he or she will try to use only diameters that can be produced with existing tools. In production, meanwhile, speeding up the punch press does not make any sense if a mountain of blanks is already waiting to pass through the press brake and the programmer is still busy programming the machine. Instead, the idea is to set up processes so that they dovetail, or interlock into a unified whole. Companies

that take steps to ensure that their corporate organization and technical infrastructure are well equipped to meet this challenge will be prepared, even when a rush job comes along. If a customer calls on Monday and wants 500 steel angles by Thursday evening, this will only mean completing an additional cycle and not a desperate race against time. CREATING THE FINISHED PRODUCT STEP BY STEP There are several process steps that have to be completed from placement of the order to delivery of the product. The main process steps are:

Design | Strictly speaking, the design stage does not start

with the idea for a part or module, but with the description of the functions that the part or module is intended to perform. These functions are specified in a document known as a requirements specification. On the basis of the specification, the design engineer comes up with several initial designs and then sketches them on paper. Often, several people will be working together on

one job, resulting in a wide variety of designs. Design engineers frequently use paper models to see which design will provide the optimum solution. After a design is chosen, it is drawn using computer-aided design software. As the design engineer models the part, the computer creates a three-dimensional shape on the screen, while taking into account material, tool, and machine data. Using the data,
the system checks whether the part can be manufactured.
Design sketch Ideas are first drawn on paper.

Design Programming Production (flat processing, bending, joining) Final processing

Design

Programming

Flat processing

Bending

Joining

Final processing

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Flat blank and bent part For flat processing: combination punching and laser cutting machine with storage system

Thin but strong Tall power poles are able to withstand hurricanestrength winds of over 120 kilometers per hour, even though the steel sheet used to construct the poles is only a few millimeters thick. The reason the poles are so strong is because of their design. They have a large number of supporting elements that make them strong.

Common problems are:

creates on the screen is three dimensional. The sheet that will be used to make the part, however, is flat. For this reason, the design stage is concluded by literally unfolding the virtual three -dimensional part. The unfolding process produces a flat sheet metal part showing how the initial sheet needs to be cut or punched. Holes, formed sections, and bending lines are also shown. This data is then transferred to the programming software.

production means creating the final shape in as few steps as possible. There are two ways of doing this. One way is through targeted part design. For example, contours and formed sections can be designed so that they can all be produced using the punch press. Another way is to use machines that combine various manufacturing techniques. On combination punching and laser cutting machines, for instance, it is possible to do forming work, while, at the same time, producing complex contours that can only be cut with the laser.

Missing tools | The part may have been designed with oval holes but only round punching tools are available at the time of machining.

Overlap | Material overlapping results in the flat layout of the part.

Collisions during bending | The workpiece collides with the machine or tool during bending.

Programming | On the basis of the unfolded part, the

programmer creates NC programs for all machines used to process the part. NC programs tell the machines what operations to perform in order to produce the part. Nowadays NC programs are no longer programmed manually. Instead, they are created semi -automatically, using programming software that contains precise information about the machine and tools. The programmer selects the machining strategy, specifies the tools, and optimizes the parameters. Then, with a simple click of the mouse, the programmer tells the programming software to generate the NC program. The programming software determines the optimum processing sequence and generates error-free NC programs. In the past, the only way to detect errors was to perform a test run on a sample piece. Today, programmers can be certain that the NC code does not contain any typos or invalid command sequences that might disrupt the program.

Bending flanges are too short | The bending line is too close to the edge of the workpiece, causing the flange to slip into the die.

Final processing | When sheet metal parts come out of

production, the sheet metal itself is still unfinished. Scratches, welding seams, and dirt are still visible on the part. The final processing stage is when the steps still required to finish the part are carried out. of data connecting everyone involved in the entire process, Typical steps that are performed:

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Holes are too close to the bending line | Holes may be so close to the bending line that they undergo deformation during bending.

The software detects these and other problems and then warns the design engineer. The final product that the engineer

nothing would work. Orders are entered and created using resource management or production planning systems. Design engineers rely on computer-aided design software to model the part. The data flows to the programming software, which is used for creating the production programs. Once the job is complete, the purchasing department may have to order more material. The accounting department, meanwhile, prepares and sends the invoice. The entire process can only run smoothly when everyone is able to access and utilize the required data at the proper time. For the design engineer, for example, this means being able to access machine, technology, and tool data during the design stage. It is also possible to standardize the design process to a certain degree. When this is done, the design engineer only needs to modify existing designs to produce similar sheet metal parts.

Cleaning up welding edges Hardening / tempering Coating Marking Painting / varnishing

As in production, the time required for final processing should be kept to a minimum. Through appropriate part design, the amount of work needed for processes such as cleaning up welding edges can be reduced. DATA FLOW The IT infrastructure has become a key factor determining the productivity of both man and machine. Today, this is also true in sheet metal processing. Without the electronic flow

Production | During production, each part must pass

through several stations. The first step in production is always flat processing. Blanks are punched out of the sheet, or a laser is used to cut them out. The blanks are then bent on a press brake. For assembled units, the final step is to
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join the individual sheet metal parts. Fast and cost -effective

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Before designing begins

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Device housings are typical sheet metal parts. Lasers can even be used to cut contours on deep -drawn sheets. Multilayer technique: multiple blanks form a complex component

Multilayer technique Solid sheet metal forms can be created by stacking multiple layers on top of each other and joining their surfaces. This technique is used for parts with complex internal structures. Each layer is first processed individually. The finished parts are then placed on top of each other and soldered together in a vacuum oven.

WHEN TO CHOOSE SHEET METAL So when does it make sense to use sheet metal parts? This is a question that companies are often faced with. The answer? More often than you think. Classic sheet metal parts typically include covers, trim, brackets, profiles, and machine components that have to be very lightweight so that they can be moved at high speeds. In cases like these, using sheet metal seems like the obvious choice. And, increasingly, sheet metal parts are also being used in areas that were previously the domain of other manufacturing methods.

Sheet metal parts can be used as a substitute for:

Cast parts made of molten metal, like radiators. Milled parts made from solid metal blocks. Parts like these include holders with numerous holes and threads.

Drop forgings made of red -hot metal that is pressed into a mold. Parts such as these include collars used in automobile transmissions to engage individual gears. Instead of forging these parts, manufacturers can weld together two sheet metal shells to form a hollow body.

There are two reasons for doing this. First, the manufacturing techniques used to process sheet metal have become so precise that staying within the required tolerances is no longer an obstacle. Second, steel has become more expensive. A large amount of material is required to produce solid parts from metal blocks. This, in turn, makes the parts more expensive. To reduce costs, companies have begun to explore alternatives like sheet metal. The advantage of sheet metal is its weight, price, and the flexibility with which it can be processed. Sheet metal parts
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It is always important to consider whether a sheet metal part should be used instead of a solid part in the following cases:

job, but there are three strategies that can help. The first strategy is always start at the beginning. This is true even if the goal is to optimize an existing part. This method opens up your mind to new and unconventional ideas. The second strategy is start with the parts function, not its present appearance or production method. This ensures that the final design includes only those elements that are actually needed. Finally, the third strategy is two heads are better than one. Inspiration frequently comes from other people in the team. Because of its great flexibility, sheet metal allows the development of many different solutions to a single problem. Maybe theres a bend that can go somewhere else, or a hole that could be shaped differently. Perhaps theres a 90 -degree angle that would be better as a 120-degree angle. Sometimes a few minor changes are all that are needed. The optimum solution usually combines an ingenious idea with thorough testing and a concrete set of rules.

Whenever a part is developed from scratch Whenever modifying an existing part that has previously been manufactured from solid material

are also more quickly available. For instance, considerably less time is required to manufacture a sheet metal part than a cast part, for which a model and mold must be prepared before the first part can even be produced. At the same time, the production quantity can be an important factor. For small to medium lot sizes, sheet metal is less expensive. For quantities over 100,000, however, cast parts are usually more economical and can also be manufactured more quickly. In the end, it is necessary to weigh all the factors involved on a part-by -part basis to determine whether sheet metal is the more economical alternative pro-

Even if a part is already made of sheet metal, it is possible to reduce costs through optimization. Combining several parts into a single part is usually more economical on the whole. Remember: small savings can mean big gains, especially when it comes to standard parts produced in big quantities. STRATEGIES FOR FINDING NEW SOLUTIONS A new solution has to be innovative and more cost effective, while providing a higher level of quality. These are the requirements that design engineers strive to meet. It can be a difficult

viding a solution that is of an equal or higher quality.

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Making it work

Design engineers are often not aware of the full range of possibilities that sheet metal has to offer. Thats why I present a variety of examples, tips, and tricks in various workshops. A lot of the people who take part in the workshops are amazed to discover just how easy it is to cut and bend a 10 -millimeter thick sheet. Others, meanwhile, are impressed by the complexity of some of the sheet metal parts. These workshops give people inspiration and insight that they can apply in their daily work. Jrg Heusel, Design

Producing functional parts while minimizing costs and manufacturing times its a goal that every sheet metal processing company strives to meet. These are also the requirements that design engineers must take into consideration when creating a part. Using different strategies and rules of thumb can be of great help here. CREATING FUNCTIONAL DESIGNS Every sheet metal part is designed to perform a specific task. For example, the part may be used to support another part or cover machine components, or it may have to move at very high speeds. Creating functional designs means designing the part so that it is able to fulfill its task. To do this, design

engineers must have extensive knowledge of sheet metal properties and take these properties into account when creating the part. Sheet metal offers certain advantages. It weighs less than solid metal blocks and is easy to shape. At the same time, this means that sheet metal is not as sturdy or rigid. If stressed improperly or subjected to excessive loads, it can bend or buckle. Special design techniques, however, can be used to lend greater strength and rigidity to the parts. In addition to resilience, appearance can also play an important role. The surfaces of external parts like covers and paneling have to be flawless. Here, too, design engineers have a few tricks they can use.

Distributing loads | If a strong load is applied to an

unfavorable spot or if it is concentrated on too small an area, the sheet metal part may become deformed. That is why parts are designed to distribute stresses to different areas of the component. This reduces the amount of force applied at each point. If the load is still too great, features such as braces can be used to reinforce certain areas.

Using tension instead of compression | Long components with small cross sections can bulge or buckle easily when subjected to pressure. This is because the force and counteracting force collide within the metal. The same components, however, remain stable when subjected to tensile force. This is due to better distribution of forces. For this reason, components are designed so that parts with small cross sections are stretched instead of being compressed.
As great force concentrated on a single spot causes the sheet to deform, it needs to be distributed. Energy absorbing areas are reinforced.

Different thicknesses | The thicker the sheet, the greater

the load it can withstand without becoming deformed. Put simply, if you need more stability, use a thicker sheet. Greater sheet thickness, however, also means more weight. Large parts often need to be lightweight and are only stressed in a few spots. That is why thicker material is used only and exactly at the stressed points. In large -scale production, tailored blanks can be used. Tailored blanks are made up of different pieces of sheet metal that are welded together into a single sheet. This means thick and expensive materials are used only in areas where they are needed most. For small and medium -sized quantities, making tailored blanks is not a cost-effective solution. Here, another approach is used. In areas where the part needs to be thicker, another
Making it all work: design engineers have to meet a wide range of demands.

sheet is simply welded on to it.

If pressure is applied to a long component, it may buckle. The component fares much better, however, when subjected to tension.

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Corrugations make cans stronger. Folds are used to reinforce ducts.

You know youve achieved perfection, not when you have nothing more to add, but when you have nothing more to take away. Antoine de Saint-Exupry

Formed sections for added stability | Forming is the

most common method of making sheet metal more stable. On tin cans, for example, corrugated areas or beading around the can make it sturdier. These corrugations can have different configurations or spacing and are used on other products as well not just tin cans. You can spot corrugations on cars or on the brackets holding up a row of shelves at the hardware

store. Parts with large surfaces such as ventilation or heating ducts can be made more stable by adding intersecting creases. When this is done, the walls of the ducts resist bulging and, at the same time, are less susceptible to vibrations. A greater degree of stability can also be attained by forming the edge of the sheet metal part. Oftentimes, simply bending or folding over the edge is all that is needed.

Closing of cross sections | Closed sheet metal structures are much sturdier than open ones. This is especially true of parts that are subjected to torsion, or twisting. For this reason, box-shaped forms should be closed wherever possible, for example, by welding together the edges.

Tension

Forces act in opposite directions, stretching the part.

Composite structures | Ribs, rods, braces and reinforcement plates can also be used to add stability to parts made of thin sheet metal. Corner or center plates are frequently used on open box structures made of profiles (tubes having a variety of cross sections) like those used to construct stands at exhibitions or trade shows. Evenly spaced ribs are used to reinforce large -volume parts.
Pressure Forces converge on a single area, compressing the part.

Joining from the inside | On sheet metal parts requiring

a flawless appearance, processing marks must not be visible. On parts like these, visible edges that are welded from the outside can prove to be problematic. To avoid having to polish them by hand, special joining methods are used to create a clean seam. Such methods include TIG welding for stainless steel or laser welding. Another alternative is to weld the edges from the inside. Here, the edges of the sheet are bent over
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Torsion

Forces pass in different directions, causing the part to twist.

so that the welding seam is on the inside.

Bending Forces act in the same direction, causing the part to bend.

Edge variations Edges can be made more robust by bending or folding them over or joining the edges at the corner.

Corner or center plates can be used to reinforce open box structures.

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If it isnt there, it doesnt cost anything. This applies, above all, to sheet thicknesses and the number of single parts that make up a component. Lutz Hartmann, Design

The visible edges of this cover are welded together using a laser. The welding seams are clean and smooth, eliminating the need for extra cleanup work.

CREATING ECONOMICAL DESIGNS The maximum allowable cost of a sheet metal part is determined before work begins on designing the part. Naturally, the more economical the part is, the better. There are two ways of achieving this. You can either save on material or cut costs in production. Economical, however, is not the same as cheap. The goal is to combine the various production factors the type of material, material consumption, time, machines, and tools in the best way possible. Production factors influence each other. One change can oftentimes have a positive effect on a number of different areas. For example, a reduction in the number of single parts used to create a module not only saves material, but also reduces production time. The following methods have proven to be successful in creating economical designs:

includes the sheet skeleton remaining between the parts and the cutouts that are produced when holes are cut in the workpiece. Design engineers can fit more parts on the sheet by designing the parts so that they nest inside each other. Depending on the design, it may be possible to fit smaller parts inside some of the larger cutouts. Enlarging a notch on the outside contour may also allow parts to be nested closer together. Parts with straight contours can be placed right next to each other and separated with a single cut. This helps to reduce scrap. The benefits of these methods are particularly apparent when manufacturing parts in large quantities or producing sets of parts for use as components in sheet metal modules.

Minimize the number of single parts | As a general

rule, it is better if components comprise a small number of complex parts than a large number of simple parts. This is because joining processes are usually very time consuming. Todays manufacturing techniques and programming software make it easy to produce even complex single parts.

Why weld when you can bend? | Welding not only takes
up valuable time, but also generates heat that could potentially warp the workpiece. For this reason, it is always a good idea to check whether an attached part can be substituted by simply bending another section. This eliminates the need for welding along with all the associated prep work such as setting up, aligning, and clamping the parts.

One part, many functions | In many cases, the sheet

metal part can be designed to fulfill two or more functions.

Minimize cleanup | Cleanup work can be reduced by

eliminating welding seams entirely, by welding sections from the inside, or by designing edges so that they are straight and smooth after welding. New manufacturing techniques such as laser welding also help to reduce cleanup work.

Minimize sheet thickness | Save material by selecting the smallest sheet thickness possible. This means lower material costs, reduced part weight, and faster production.

Often, these parts only need some additional holes or larger recesses in order to perform a different task. Advantages: larger quantities can be produced and only one storage location is needed.

Use the same sheet thickness | Wherever possible, the

single parts making up a component should all have the same sheet thickness, so that they can be produced from a single sheet in one work cycle. When this is done, an entire sheet can be used for flat processing instead of portions of several different sheets. This is especially important for small sheet metal fabricators who handle each job individually. It not only makes purchasing and storage easier, but also cuts down on transport between the storage bay and the machine. Also, it takes less time to set up the machine.

Maximize nesting potential | Everything left over after

the parts are punched or cut out of the sheet is scrap. This

Using design to reduce scrap: designing parts so that they nest closer to one another is a way to maximize sheet utilization.

Alternatives to welding: flanges can be bent and side elements can be secured in place using pegs that fit into holes.

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Housing with different ventilation openings Microjoints: thin support pieces keep punched parts from falling out of the sheet skeleton.

YOU DESIGNED IT. NOW CAN YOU PRODUCE IT? When designing a part, design engineers not only have to keep in mind the function and cost of the part, but also how it is going to be manufactured. Here, there are a number of different strategies that engineers can rely on.

same time, there are certain joining techniques that reduce the amount of prep work involved in processes such as welding. Instead of using a device to position multiple parts and secure them in place, you start by fitting the matching parts together. Now all that is needed is a simple welding jig to hold the parts securely in place.

Allow extra space for bending zones | When a sheet

is bent, the metal on the inside of the bend is compressed. This causes the material at both ends of the bend to be pushed outward, which, in turn, may lead to inaccuracies. To prevent this from happening, small recesses are designed into the ends of the bending zones so as to provide extra space for deformation. Extra space is frequently provided for bending zones, regardless of whether two edges meet at a corner or whether a flange is bent upwards. This produces much better corners, while permitting greater freedom in the selection and arrangement of bending tools. There are a number of ways to create extra space for bending zones. A punch press can be used to punch round holes at both ends of the bending line. Or a laser can be used to cut fillets, which are more complex. This makes corners more attractive after the parts are bent.
Certain areas can be notched in order to obtain better corners.

Microjoints | The idea of using microjoints was a solution

initially developed for laser cutting. Microjoints are narrow tabs located between the workpiece and the sheet. They hold the workpiece in the sheet and keep it from becoming displaced. After the sheet has been processed, the parts are snapped out of the sheet by hand. There are other ways that microjoints can be used. For example, they can serve as production aids in the manufacture of small angles. The blanks remain connected by microjoints.
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Use existing tools | Especially when it comes to small

and medium-sized quantities, acquiring new tools is not a worthwhile investment for a company. In most cases, it is not even necessary. For many shapes and functions, there is more than one alternative. It is the design engineers job to find the alternatives that make do with existing tools. A good example is the ventilation holes on a PC housing. A punch press that permits tool rotation can be used to arrange simple oblong holes in a radial pattern. An alternative would be to arrange small squares in rows or use a louver tool to produce ventilation slots.

They are bent together and then separated by hand. Another example is creating bends in parts where accuracy is not crucial. Microjoints are placed along the bending line, making it possible to bend the parts by hand.

Everything on the punch press | When solid parts are

substituted by sheet metal parts, these parts often still require machining of some kind. Holes still have to be drilled, and threads have to be cut. The most cost -effective solutions, however, do not require any cutting at all. This can be done, for example, by using the punch press to form threads instead of cutting them.

Life after production | The true life of a sheet metal

part actually begins after production. For this reason, it is important for design engineers to take into account aspects such as transportation, storage, assembly and disassembly. For example, parts that are transported and stored in large numbers should be designed so that they can be stacked on
Joining made easy: there is only one way of joining the parts together.

Use positioning and joining aids | Where was the part

supposed to go again? Was it on the left or the right? Questions like these can be avoided by designing the parts so that there is only one way to put them together. This is done
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by using matching holes and pegs to assemble parts. At the

top of each other to save space.

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Virtual manufacturing: the movement of the laser cutting head is simulated on a computer.

FIVE WAYS TO PRODUCE AN ANGLE Design is an art. Designers not only have to know plenty of good tricks, but also when to use them. Sheet metal is so versatile and the parts are often so complex that engineers may not immediately recognize all the possibilities. Jrg Heusel,
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design engineer and instructor at TRUMPF Werkzeugmaschinen GmbH + Co. KG in Ditzingen, knows just how challenging this can be. He conducts workshops in which participants

Production simulations | Many types of design and

programming software enable users to simulate production. This allows design engineers to test sheet metal parts as often as necessary to identify problems. Today, computer simulation has become an indispensable pre-production tool, particularly for the manufacture of complex parts. The use of simulations ensures that workers in production no longer have to stand next to the machine for hours trying to figure out the optimum production sequence for a sample piece. Company directors will also be pleased to see that the machine is being used to produce something instead of completing endless test runs.

search for new solutions for their existing parts. The people in my workshops frequently ask me to demonstrate the many possibilities available using only a simple example, says Jrg Heusel. His response is to show them five ways to produce an angle. Angles are always positioned in areas where two surfaces meet. They hold the surfaces in place and help support them when they are stressed. If the angle is subjected to extreme loads, it may need to be reinforced. There are many different ways of doing this. Method 1 | Using cross braces The first way to make angles sturdier is to weld a cross brace down the middle of the angle. What this means for production: two parts have to be punched or cut with a laser; the angle is bent; and the cross brace is positioned and welded to the angle, producing two seams. Not bad, but how can we find a better solution? Method 2 | Using joining aids This method is aimed at reducing the amount of positioning and welding work. The cross brace has two tabs, and the angle has two rectangular slots. The tabs are inserted into the slots, and the joint is welded from the outside at two points. Method 4 | The answer is just around the corner So what do you do if the brace absolutely has to be positioned down the middle of the angle? The solution is easier than you might think. This time, two bends are made to bring the brace into Method 3 | One part only Two parts generally mean more work than one part, because they are often produced separately and then put into temporary storage. So lets try using one part instead of two. Two supports on the sides of the angle now replace the cross brace. As before, these sides are also designed with joining aids that facilitate welding. The angle is punched or laser cut and then bent three times. The sides are then welded. Although we have not significantly reduced the amount of work required to produce the angle, we now have a part that is very robust. Method 5 | Dont forget what the parts made for Lets look back for a moment at the function of the angle. It has to be sturdy and be able to support a load. Wait, does the angle even need a cross brace? Or would a simple, wellplaced corrugation do the trick? If cross beading is enough, you could consider first punching or cutting the rectangular parts from the sheet. Afterwards, the edge and corrugation can be produced in a single bending process. This approach not only minimizes production time, but also makes it possible to stack and store parts to save space. position. Here, too, a tab is used to fit the brace to the angle. This results in a single part that requires only three bends. Now, all thats left to do is to weld the brace at one single point.
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Angle with welded cross brace for reinforcement

The cross brace has tabs that help to join parts.

One -piece design: sides instead of cross brace.

Three bends are used to produce a center brace.

One bend only: cross beading instead of cross brace

Knowledge transfer | Design engineers who have extensive experience in the field are able to rely on their expertise to tackle each new task. Working together with colleagues in production, they have gained knowledge of the attainable tolerances and learned which hole spacings, edge formats, side lengths, and bending radii work and which ones dont. To ensure that this knowledge can be used by others, it has to be documented. Ideally, this is done using the design software, which helps to integrate individual experience and safeguard company standards.

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Creative in cyberspace

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Still in the design stage and yet incredibly real: developers discuss their designs in virtual space.

Virtual space or cave Complex computer and projection technology make it possible: multiple projectors are used to display the image of a part on several different screens. The people in the cave wear special glasses that combine the images on the various screens into a single three -dimensional image. Cameras, meanwhile, are used to monitor the position of the observer. If the observer moves, the image changes accordingly. This allows the observer to examine the part from different angles: from above, from below even from the inside!

The changing nature of the job | The job of a design

engineer is constantly changing. Each new material, tool, and manufacturing technique adds to the ever-growing array of design possibilities for sheet metal parts. At the same time, new design software and virtual modeling methods are changing the way design engineers work. Even so, it usually takes years before new technology becomes known among professionals in the field and is then applied. Many companies feel that the engineering design programs offered by various schools do not give enough attention to sheet metal design. To fill the gap, an effort has been made to provide workshops and special training courses.

Virtual space | A number of companies are already using

virtual space to present and elaborate their product models. Multiple projectors are used to display the image of a part on several screens at the same time. People in the room wear special glasses that combine the different images into a three-dimensional model, just like in a 3D movie. People in the automotive industry have found a way to project an entire vehicle interior around a simulated drivers seat. The virtual interior makes it possible to see how well the different elements of the design fit together or whether the steering wheel is properly positioned. The simulation makes it easy to move any elements that dont fit. Mechanical engineers can also use virtual space to present components or entire machines. This allows them to discuss the models with other departments. As the technology becomes easier to use and the costs become lower, use of virtual space will continue to grow. Even so, computer-aided design software will remain crucial for the design of the part. This is because most of the work involved in designing a part is actually drawing it.

Automated design? | Computer technology has come a

long way, and is still advancing every day. Nevertheless, computer software is no substitute for human creativity. Design software will remain a tool that design engineers use to make modeling easier, while enhancing the precision and efficiency of their work. At the same time, the data interfaces between the resource management system, computer-aided design software and programming software continue to undergo optimization. The goal and essence of the design process, however, remains the same: creative, intelligent people working to find innova1

tive solutions.

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