Sheet Metal Selection Guide for Different Applications

Sheet Metal Selection
for
Different Applications
Dr.N.Ramani
NTTF
SHEET METAL SELECTION 1

Contents:
•Introduction to Design per se
•Sheet Metal Alternatives for Selection
•Characteristics of different Sheet Metals
•Examples of Applications

DFA ?
Reason for its importance?

DFB ?
Design for Beauty

DFC ?

DFC ?
DESIGN FOR COST

DFM ?

DFM ?
MFG COST
• RAW MATERIAL
• EQUIPMENT
• LABOR
• SCRAP
• REWORK
Design For ‘S’
Design for Simplicity

Case of a long letter

Design For A to Z

Design For ‘X’

Design For ‘X’
Which is the most important “X” ?

Design For ‘X’
DFC !
Design For ‘X’
•Customer designed Car!

•Expansion of “FORD”
• DFT >>>> DFM !

Design for
•Customer Satisfaction
•Manufacture
•Assembly(Disassembly?)
•Sales Appeal(Color(Tempo), Styling)
•Cost (to balance with “Performance”)(“Value for…”)
•Maintenance(Scooty Spark Plug)
•Recycling?(DFX)

Domino Effect… X= A to Z
Z A B C
Y D
E
X
W F
V G
U DFX H
T I
S J
R K
Q L
PSHEET METAL N M
O SELECTION
Compromise? 16
Criteria for Selection of Sheet Metal:
•Functionality
•Formability
•Finance

Criteria for Selection of Sheet Metal:
•Formability
•Capability of being extensively deformed into
intricate shapes without fracture or defects in the
finished part.
•The manufacturing operation by which this is done:
•Press forming
•Deep drawing
•Stamping

Sheet Metal
1. Preliminary Analysis of Shape Formability?

2. Uniform Wall Thickness is OK?
• Any extra wall thickness requirement (e.g.for
reinforcement) can be met by welding of an
extra part?

Sheet Metal
Ferrous Non-Ferrous

Sheet Metal
Ferrous Non-Ferrous
Carbon Alloy Stainless

Steel Steel Steel

Sheet Metal
Ferrous Non-Ferrous

Steel Steel Steel
Hot Cold
Rolled Rolled

Sheet Metal
Ferrous Non-Ferrous

Steel Steel Steel
Al Cu Brass Bronze

Sheet Metal
Ferrous Non-Ferrous

Steel Steel Steel
Al Cu Brass Bronze
Nickel Silver Gold

•The other name for “Factor of Safety”?
•Some useful tables to do “preliminary analysis”

for selection / suitability of a metal

Yield Point Comparison
# Metal Yield Point Range
1 Carbon Steel
2 Alloy Steel
3 Stainless Steel
4 Aluminium
5 Copper
6 Brass
7 Bronze

UTS Comparison
# Metal UTS Range in Mpa*
1 Structural Steel 345 - 450
2 Alloy Steel
3 Stainless Steel 18 - 8 585 - 655
4 Aluminium 270 - 315
5 Copper 220 - 470
6 Brass 275 - 825
7 Bronze
*Please check this value Page 2.6 Bralla

Tm Comparison
# Metal Tm Range
1 Carbon Steel
2 Alloy Steel
3 Stainless Steel
4 Aluminium
5 Copper
6 Brass
7 Bronze

Cost Comparison
# Metal Cost / kg in Sheet Form
1 Carbon Steel
2 Alloy Steel
3 Stainless Steel
4 Aluminium
5 Copper
6 Brass
7 Bronze
Cost / kg Vs Kg
Stiffness / Weight Ratio
# Metal Weight for equal
Stiffness
1 Carbon Steel 7.95
2 Alloy Steel
3 Stainless Steel
4 Aluminium 3.66
5 Copper
6 Brass
7 Bronze
Specific Gravity Comparison
# Metal Specific Gravity
1 Carbon Steel 7.8 – 7.9
2 Alloy Steel - do -
3 Stainless Steel - do -
4 Aluminium 2.55 – 2.75
5 Copper 8.8 – 9.0
6 Brass 8.4 – 8.7
7 Bronze 8-14% Tin 7.4 – 8.9
Pareto Principle
20% Vital Few

Factors
80 %
80% Trivial Many
Factors
20 %
Cause Effect
Input Output
Effort Result
Pareto Analysis of All Sheet Metal Applications
Frequency
80 %
20 %
Steel Others

Pareto Analysis of All Steels
Frequency
80 %
20 %
< 1% 1–2% % Carbon

Pareto Analysis of All Sheet Metal Applications wrt %C
Frequency
80 %
20 %
< 0.3 Higher % Carbon

Difference between “Plate” & “Sheet”?

Meaning of ‘Structural’ or ‘Constructional’ Steel”?

Structural Steel:
•Fusion Weldable
•Resistance Weldable
•Machinable

Steel
•Ingot
•Slab
•Plate
•Strip
•Sheet

Classification of Carbon Steel Sheet Grades
# Symbol QUALITY
1 O Ordinary
2 D Drawing
3 DD Deep Drawing
4 EDD Extra Deep

Drawing

SUPPLY CONDITION OF COLD ROLLED
CARBON STEEL SHEET
# GRADE CONDITION
1 O Mill or Trimmed
Edges
2 D Annealed & Skin
passed
3 DD - do -
4 EDD - do -

Temper Designations of CR Low Carbon Steel Strips
# Temper Temper Processing

Designation
1 H Hard Heavy CR
2 ½H Half CR + A + CR
Hard
3 ¼H Quarter - do -
Hard
4 SP Skin A + Light CR
Passed
5 A Annealed Final ‘A’
Pressed Parts
Prototypes
Short Run Jobs
Long Run Jobs
Part Design Method of Manufacture (Rect. Box)

Pressed Parts
Prototypes Production Pressed Parts

•Temp.
Tooling Short Run Jobs Long Run Jobs
•Design likely •Small Volume •Large Volume
to change
after Testing •Split up operations •Combined /
Sequential
•(Laser-cutting)
Operations
•Bridge Tooling
•(Toyota Example)
SHEET METAL SELECTION

•Tailored Blanks
Pressed Parts
Prototypes
Short Run Jobs

Cost of die > Cost
Cost Long Run Jobs
Of Jobs produced
Per
Part Cost of die < Cost
Of Jobs produced
Number of Parts

Steels for Pressing
< 0.1%C < 0.3%C
Severe forming
operation End of
Coining
< 0.15%C
2t bending in any direction ;
Alu Killed?
0.15% -- 0.25%C
180 deg bending
Per. To grain-flow
Aluminum Killed Steel:
• Steel that has been fully killed
• Fully deoxidized
• By the addition of Mn / Si / Al
• Practically no evolution of gas from the reaction
between C & FeO3 during solidification
• Sound ingots are obtained
Opposite of Aluminium Killed Steel = ?

Rimmed Steel
•Low C steel that has not been completely
deoxidized before casting;
•Gas is evolved during solidification;
•Consequent volume increase counteracts
solidification shrinkage;
•Inclusions are concentrated in the center,
•which close up during rolling.

Angle between test direction and rolling direction, degrees
Angle between test direction and
SHEET METAL rolling direction, degrees
SELECTION 55
‘Preferred’ Thicknesses of cold rolled Steel Sheets
& Strips (?)
1.5 Vs 1.6 mm ? SWG?

Comparison between Tables 6 & 7?

Comparison between Tables 6 & 7?
IS 513:1994
Cold rolled Low Carbon Steel Sheets & Strips-
Specification

IS 7226:1974 (Reaffirmed 1997)
Cold rolled Medium, High Carbon & Low Alloy Steel
Strips For General Engineering Purposes

Pre-finished steel sheets:
•Coated
•Galvanized
•Tin Plated
•? (Washing Machine, Fridges)

Iron:
•Soft stuff in pure form
•Add a little C & you get a material that is almost as brittle as Glass
or as Ductile & Tough as Boiler plate
•‘Heat Treat’ means heating steel to ~ 800 deg C to dissolve the
Carbon & quenching (Rapid cooling, often by dropping into cold
water) & Tempering
•Reheating to a lower temperature & holding it there
•Quenching turns steel into hard brittle ‘Martensite’
•Tempering slowly restores the toughness & brings hardness
down
•Control of Temperature & Tempering Time gives control of
properties. It is really wonderful what 1% Carbon can do
75
Carbon Steel:
•Strong, Tough, Easily Formable, Economical
•Alloys of Iron with C , a little Mn, Ni, Si
•Low carbon or ‘Mild Steels’ have < 0.25% C
•Cheapest of all structural metals
•Used for building ships, Steel-framed buildings-
reinforcement
•Composition: Fe / 0.02 –0.3% C

Low Alloy Steels:
•The cooling rate has to be fast >200 deg C / Sec
for plain C Steel for hardening
•There is no difficulty in transforming the surface of a component
to Martensite, but the interior cools more slowly because heat is
to be conducted out
•The inside does not cool fast enough for components thicker
than a few mm. The problem is overcome by alloying
•Add a little Mn, Ni, Mo, Cr & the critical cooling rate comes
down, allowing thick sections to be hardened & later tempered
•Steels alloyed for this purpose are called ‘Low Alloy Steels’.
The property they have is ‘Hardenability’
•Composition:Fe / < 1.0C / < 2.5 Cr / 2.5 Ni / < 2.5 Mo / < 2.5 V
Medium Carbon Steel
•0.25 – 0.7 % C
•Hardens when quenched
•Hardenability measures the degree to which it can be
hardened in thick sections
•Used in for rail road tracks on an enormous scale
•Composition: Fe / 0.3 – 0.7 % C

High Carbon Steels:
•Carbon 0.5 – 1.7 %
•Harden when quenched ( Quality giving great control over
properties)
•Applications: Cutting Tools, Chisels, Cables, ‘Piano wire’,
Springs
•Composition:Fe / Carbon 0.5 – 1.7 %

Stainless Steels:
•Alloys of Iron with Cr, Ni & often 4 – 5 other elements
•Alloying transmutes plain carbon steel that rusts & is prone to
brittleness below room temperature into a material that does
neither
•Resist corrosion in most normal environments & remain ductile
to low temperatures
•Composition: Fe / C < 0.25 / Cr 16-30 / Ni 3.5 – 37 / Mn 10 +
Si SHEET METAL SELECTION 80
STAINLESS STEEL
•Not a single alloy, but rather the name applies to a group of iron
based alloys containing a minimum of 10.5% chromium
•Other elements are added and the chromium content increased to
improve the corrosion resistance, improve heat resisting properties,
enhance mechanical properties, and/or to improve fabricating
characteristics.
•There are over 50 stainless steel grades that were originally
recognized by the American Iron and Steel Institute (AISI) and are
detailed in a designer handbook, "Design Guidelines for the
Selection and Use of Stainless Steel", available from the Specialty
Steel Industry of the United States (SSIUS). 81
AUSTENITIC STAINLESS STEEL GROUP
•Contains chromium and nickel and is identified by the
Type 300 series.
•Grades containing chromium, nickel and manganese are
Type 200.
•These two types have different compositions and
properties, but many common characteristics.
•They can be hardened by cold working, but not by heat
treatment.
•In the annealed condition, all are essentially nonmagnetic.
•They have excellent corrosion resistance and unusually
good formability.
•Type 304 (18% chromium - 8% nickel) and Type 316 (16%
chromium - 10% nickel - 2% molybdenum) are the most
82
widely used grades in this group.
Ferritic Stainless Steel group
•The ferritic stainless steels are identified by the Type 400 series.
•They cannot be hardened by heat treatment.
•They are straight chromium alloys and only moderately hardened
by cold working.
•This group is magnetic and has good ductility and resistance to
corrosion.
•Type 430 (16% chromium) is the general purpose stainless steel
of the ferritic group.
Martensitic Stainless Steel Group
•Is also identified by the Type 400 series

•Hardenable by heat treatment.
•Magnetic and resist corrosion in mild environments.
•The ductility of this group is fair to good.
•Type 410 (11.5% chromium) is the most widely used alloy
of this group.

STAINLESS STEEL STRIP :
•Hot rolled stainless steel strip is a semi-finished product
obtained from the hot rolling of slabs or billets and is
produced for conversion by cold rolling. ( Salem?)
•Cold rolled stainless steel strip is manufactured from hot

rolled, annealed and pickled strip by cold rolling on
polished rolls.
•Depending on the thickness desired, the cold rolling
requires various numbers of passes through the mill to
effect the necessary reduction and to secure the desired
surface characteristics and mechanical properties.
•Only three rolled (unpolished) finishes (No. 1, No. 2 and

bright annealed) and one polished finish (mill buffed) are 85
commonly supplied on stainless steel strip.
Stainless Steel Strip Finishes:
•No. 1 finish is produced by cold rolling, annealing and pickling.
•Appearance varies from dull gray matte to fairly reflective,
depending largely on stainless steel type.
•This finish is used for severely drawn or formed parts, as well as for
applications where the brighter No. 2 finish is not required, such as
parts to be used at high temperatures.
•No. 1 finish for strip approximates No. 2D finish for sheet.
Stainless Steel with No. 2 finish
•Produced by the same treatment used for No. 1 finish followed by
a final light cold rolling pass, which generally is done using highly
polished rolls.
•This final pass produces a smoother and more reflective surface,
the appearance of which varies with stainless steel type.
•No. 2 finish for strip is a general-purpose finish widely used for
household appliances, automotive trim, tableware and utensils.
•No. 2 finish for strip approximates No. 2B finish for sheet.
Stainless Steel with Bright annealed finish:
•Bright, cold rolled, highly reflective finish retained by final
annealing in a controlled-atmosphere furnace.
•The purpose of atmosphere control is to prevent scaling or
oxidation during annealing.
•The atmosphere usually consists of either dry hydrogen or
dissociated ammonia

Stainless Steel with Mill-buffed finish:
•Highly reflective finish obtained by subjecting either No. 2 or
bright annealed coiled strip to a continuous buffing pass.
•The purpose of mill buffing is to provide a finish uniform in color
and reflectivity.
•It also can provide a surface receptive to chromium plating.
•This type of finish is used chiefly for automotive trim, household
trim, tableware, utensils, fire extinguishers and plumbing fixtures.
Coil Slitter Stretch-wrap Packing
Cold Rolled Stainless Steel Finishing

Aluminium Sheet:
•First of the ‘Light Alloys’ (Which are the other two?)
•Third most abundant metal in earth’s crust (Which are the
other two?)
•Extracting costs much energy (Story of Coca-Cola Can)
•After Steel the most important metal in the Economy
•Mainstay of Aerospace Industry
•All Al Cars?
•Composition: Al + Alloying Elements Mg, Mn, Cr, Cu,
Zn, Li SHEET METAL SELECTION 92
Monocoque frame of precision welded from
pressed sheet is both made from Al Alloy &
Mg Alloy. Mg Frame is 30% lighter than Al
one (Tube making process?)
Magnesium:
•Second of the Light-Metal Trio (with Al & Ti)
•Computer case made from Mg is just 2/3 as heavy as one
made from Al
•Mainstay of Aerospace Engineering
•Composition: Mg + Alloying Elements Al,Mn,Si, Zn, Cu,
Li, Rare earth elements

Electrical contacts
Copper / Cu Alloy Strips:

•Characterized by excellent Ductility & Thermal conductivity
•Bronze Age : 3000 BC –1000 BC
•Cu-Zinc Alloy (Brasses)
•Cu-Tin Alloys (Bronzes)
•When % Cu > 99 %, we use the word Copper + Something
•Copper-Beryllium; Copper-Nickel
•Composition: Cu with up to 40% Zn or 30% Sn, Al or Ni 94
Nickel:
The 5Cent piece is called Nickel, made of pure Ni
Ductile,silvery, easily formed by Stamping / Rolling / Forging
Hard when worked
Good Resistance to Corrosion
Largest single use in production of SS (stabilizes the face centered
cubic structure steel giving ductility & corrosion resistance)
Next large scale use in manufacture of Super Alloys (Ni based alloys
having good Strength even at elevated temperatures required for jet
engine parts)
Third use? SHEET METAL SELECTION 95
Cupro-Nickel Coins
Composition:
1938 - 1942, 1946 to date 75% copper 25% nickel
1942 - 1945 56% copper, 35% silver, 9% manganese
Weight:
5g
1942 -1945 .056256 oz. of pure silver
Diameter: 21.2mm
Edge: Plain

Gold & Silver
Coins

Titanium: (Specific Gravity 4.5)
•Seventh most abundant metal in earth’s crust
•Extracting the metal from its oxide is difficult
•Third member of Light-Alloy Trio
•Most expensive of the trio ( >1000% Al)
•High Melting Point @ 1660 C
•Light, Resists Corrosion, protected by a thin film of oxide on its
surface
•Exceptionally strong for its weight
•Can be used @ temperatures up to 500 C (Air compressor blades of
Gas Turbine Engines)
•Unusually poor thermal & electrical conductivity, having low CTE
•Composition: Ti + Allying Elements Al, Zr, Mo, Si, Sn, Ni, Fe, V
Thank You

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Sheet Metal Selection

SHEET METAL SELECTION 1

SHEET METAL SELECTION 2

Reason for its importance?

SHEET METAL SELECTION 3

Design for Beauty

SHEET METAL SELECTION 4

SHEET METAL SELECTION 5

DESIGN FOR COST

SHEET METAL SELECTION 6

SHEET METAL SELECTION 7

Design for Simplicity

SHEET METAL SELECTION 9

SHEET METAL SELECTION 10

SHEET METAL SELECTION 11

Which is the most important “X” ?

SHEET METAL SELECTION 12

Design For ‘X’

Design For ‘X’

•Customer designed Car!

• DFT >>>> DFM !

SHEET METAL SELECTION 15

SHEET METAL SELECTION 17

SHEET METAL SELECTION 18

1. Preliminary Analysis of Shape Formability?

SHEET METAL SELECTION 19

SHEET METAL SELECTION 20

Carbon Alloy Stainless

SHEET METAL SELECTION 21

Carbon Alloy Stainless

SHEET METAL SELECTION 22

Carbon Alloy Stainless

SHEET METAL SELECTION 23

Carbon Alloy Stainless

Nickel Silver Gold

SHEET METAL SELECTION 24

•Some useful tables to do “preliminary analysis”

SHEET METAL SELECTION 25

SHEET METAL SELECTION 26

SHEET METAL SELECTION 27

SHEET METAL SELECTION 28

20% Vital Few

SHEET METAL SELECTION 33

< 1% 1–2% % Carbon

SHEET METAL SELECTION 34

< 0.3 Higher % Carbon

SHEET METAL SELECTION 35

SHEET METAL SELECTION 36

SHEET METAL SELECTION 37

SHEET METAL SELECTION 38

SHEET METAL SELECTION 39

4 EDD Extra Deep

SHEET METAL SELECTION 40

SHEET METAL SELECTION 41

# Temper Temper Processing

Long Run Jobs

Part Design Method of Manufacture (Rect. Box)

Prototypes Production Pressed Parts

SHEET METAL SELECTION

Short Run Jobs

SHEET METAL SELECTION 45

Opposite of Aluminium Killed Steel = ?