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pm | | Sheet Metal Stamping Process (18th Nov 22 at 1:59am UTC) | | Sheet Metal Stamping Process
The process of turning sheets of metal into a useful part or component is called sheet metal stamping. The metal is fed into a press, where the stamping tool, also known as a die, creates the desired shape. The die is pressed into or through the metal with tremendous force. The force used in the process is measured in tons.
Except for some specialized processes, sheet metal stamping doesn’t use heat. Instead, it is done with a cold-forming technique. Even though no heat is used, the part can come out hot because of the friction that’s created between the metal and the die from the force of the press.
There are basically only three components to sheet metal stamping—the sheet metal, die, and press machine—but any single part can require multiple steps to arrive at its final form. The following guide explains a few common processes that might occur during metal stamping.
Forming: Forming describes the process of transforming the flat metal into another shape by applying force. It is accomplished in one of several ways, depending on the design specifications for the part. With a series of operations, the metal can be altered from a relatively simple shape into a complex one.
Blanking: Blanking is the most basic technique and initiates when the sheet or blank is fed into the press where the die cuts out the desired shape. The resulting piece is called a blank. The blank may be the desired part, also known as a fully finished blank, or it may continue to the subsequent step of forming.
Drawing: Drawing is a more complicated operation and is how vessels or deep depressions are formed. Tension is used to carefully draw the material into a cavity to change its shape. Though the material might stretch while it’s drawn, technicians try to avoid stretching as much as possible to keep the material intact. Sinks, cooking equipment, and oil pans for vehicles are usually made with drawing.
Piercing: Piercing is almost the opposite of blanking, but instead of saving the blanks, technicians use the material around the outside of the punched area. As an example, think of cutting biscuits from a rolled-out circle of dough. During blanking, the biscuits are saved; during piercing, on the other hand, the biscuits are discarded, and the hole-riddled remains are the desired outcome.
In the stamping process, sheet metal is transformed into complex parts using highly specialized computer-aided drafting and manufacturing programs. Sheet metal stamping produces superior, resilient, heavy-duty parts quickly and efficiently. The results are so precise, they’re typically more reliable and consistent than manual machining.
The following industries use components that are created via sheet metal stamping:
Automotive
Renewable energy
Medical
Industrial
Aerospace
Hardware
Home improvement
This list is by no means exhaustive. There is a considerable demand for sheet metal stamping, and the range of industries that depend on it is vast.
What is Electrical Fitting & How it Works
Maybe you never thought about this issue seriously, but what happens if we don't have fittings?
(1) Easy to Connecting Conduit & Running Wire
If you don't have a bend or reducer on hand,you will be crazy.
We can't arrange the pipes and wires in a straight line for the whole house which is determined by the geometry.In most cases,it is necessary to turn at the corner and to arrange the wire under or on the wall such as ceiling lamp installed.
However,you need to repair part of the tube sometimes for it is damaged,but you can not replace all of them instead of repair part of a pipe.So the fittings can help you to do this.
(2) Protect Wires
Good quality conduit can be kept safe of your wire,but it need to match with nice quality fittings too.For example, If you encounter a 90° corner, there is no bend or related fitting on hand.When we run the wire directly and through the pipe, this may cause additional bending and pressure on the wire insulation layer,resulting in whitening of the insulation layer and faster aging.Once the insulating layer fails, there may be a risk of electric shock.
Moreover,a well-sealed conduit will reduce the probability of water and dust entering,which not only keeps the pipe clean, but also protects the safety of the wires.
(3) Easy to Pull the Wires
If you need to modify the direction or position of the previous wiring for some reason,and we supposed you do not have any special tools.It is the wrong way to pull the wire directly from the right-angle wire tube because this will damage the insulation layer of the wire during the process of pulling the wire,which may cause danger in some cases.Moreover, pulling the wire in this way is easy to get stuck and increasing in construction time.
But if you add fitting when you layout the wires in the early stage,it will be different.The inner wall of the high-quality fitting is smooth and will not damage the wire insulation. More importantly,fittings can make the wires have a certain angle inside, which makes it easier to pull out the wires.
We know that people may not pay much attention to the quality of fittings in most cases, especially when it comes to replacement and maintenance at home.
Considering the amount is very small,so you just go to the nearest mall or store to buy a replacement.Therefore,we recommend buy branded products and pay attention to the specifications.So that you will not worry about used for save your time and money.If you want to learn more about the manufacturing process and process of electrical conduit,we mentioned in the previous post, you can read the post named ‘How to Make an Electrical Conduit’ to learn about the manufacturing process of electrical conduit and how to quickly identify the quality of PVC conduit.As for fittings, because most of them are injection molding processes, the identification method is similar.
Difference Between Galvanized and Hot Dip Galvanized
The key difference between galvanized and hot dip galvanized is that most galvanized materials have a smooth and sharp finishing, whereas hot sip galvanized structures have a rough finishing.
Galvanization is a process of preventing metal surfaces from corrosion. After the completion of galvanization, we say that the surface is “galvanized” if it is done via the usual procedure. However, if we use hot dipped method, we call it a “hot dip galvanized surface”.
A galvanized surface is a metal surface that has a zinc layer for the protection from corrosion. We call the process of applying this zinc layer “galvanization”. Moreover, this application is done on steel or iron surfaces.
There are different types of galvanization, including:
Hot dip galvanization – immersion of the item in molten zinc
Continuous galvanizing – a form of hot dip galvanization, but this method forms a thinner zinc layer; thus, the corrosion resistance is comparatively less
Thermal spray – spraying semi-molten zinc on to the item
Electroplating – using the item and zinc metal as electrodes in an electrochemical cell
Mechanical plating – electroless method to deposit the coating using mechanical energy and heat
Hot dip galvanization is the process of coating a zinc layer on a metal in order to protect that metal from corrosion. We can denote it as HDG. This process has three major steps, as follows:
Surface preparation
Galvanizing
Inspection
In the surface preparation step, we have to hang the steel item using wires or place in an appropriate rack. Thereafter, the steel goes through three cleaning steps: degreasing, pickling and fluxing. The degreasing step removes the dirt on the steel surface. Pickling step removes mill scale and iron oxide. Later in fluxing step, it removes any other oxides present on the steel surface and forms a protective layer which can avoid any further oxide formations.
What is Electrical Cable?
The cable that is used for the transmission and distribution of electrical power is known as the electrical power cable. It is used for the transmission of high voltages in places where overhead lines are impractical to use.
The power cable is made of three main components, namely, conductor, dielectric, and sheath. The conducting path for the current in the cable is provided by the conductor. The insulation or dielectric withstands the service voltage and isolates the live conductor with other objects. The sheath does not allow the moistures to enter and protects the cables from all external influences like chemical or electrochemical attack and fire.
Various types of Cables are used everywhere for various applications. Not all cables perform the same application. The function of a cable depends upon the type of cable. The electrical cables are made of aluminium or copper wires protected by an insulating coating which can be made of synthetic polymers.
Cables are classified into 5 types depending upon their purpose as follows:
Ribbon Electric Cables
It consists of multiple insulated wires running parallel with one another and is used for transmission of multiple data simultaneously. For example, this is used to connect the CPU with the motherboard and are generally used for interconnection of networking devices.
Shielded Cables
It consists of 1 or 2 insulated wires which are covered by a woven braided shield or aluminium Mylar foil for better signal transmission and removing irregularities in the frequency of power and external interference in radio. These cables transmit high voltage electric current and are protected by a shield.
Twisted Pair Cables
It has two or more insulated copper wires which are twisted with each other and are colour-coded. These types of wires are usually used in telephone cables and the resistance to external interference can be measured by the number of wires.
Coaxial Cables
This consists of solid copper or steel conductor plated with copper which is enclosed in the metallic braid and metallic tape. This is entirely covered with an insulated protective outer jacket. These type of cables are used for computer networking and audio-video networking.
Fibre Optics Cable
There are these types of cables which transport optical data signals from an attached light source to the receiving device. We are pretty much aware of what is an optical fibre and its uses in a wide variety of applications.
Dry-Core ADSS Cable Placement
ADSS(All Dielectric Self-Supporting) cable is fully dielectric for use in the aerial plant. As compared to typical cables used in the aerial plant, ADSS cable is designed with its strength member and support member to be inherent to its circular cross-section. It is supported by its own inherent strength. Since it uses all non¬metallic materials, it generally can be used without concern about power coupling e ects and bonding and grounding issues. This makes ADSS cable popular on electrical utility rights-of-way suspended from poles or towers. It is constructed with a multi-tube cross-section to support either ribbon or loose optical Fibres. The ADSS cable’s outer jacket can be either a single or a dual jacket with an embedded non-metallic strength member. The installation methods for ADSS cables are essentially the same as those used for other aerial optical cables, except ADSS cables are not lashed or supported o a messenger strand. Special care must be taken during installation not to exceed the cable’s maximum pulling tension, its minimum bending radius, and other mechanical strength limitations. It is necessary to avoid any jacket damage which can expose strength members within the jacket and reduce the long-term cable performance. The IEEE Guide to the Installation of Overhead Transmission Line Conductors will provide additional relevant information about ADSS installation practices.
If the cable is to be placed on structures with power transmission lines, the safety practices of the power utility company must be followed in addition to those of the telecommunications company. All national, state, and local requirements, the safety procedures of the power utility and the communications company shall take precedence over information contained in this document. Leakage current from the phase conductors can produce currents on the ADSS cable or hardware, especially during wet weather. Equipment associated with the ADSS cable and the cable itself must be properly grounded before it is touched. ADSS cable shall not be installed on energized towers during wet weather because current leaking from the phase conductors can produce dangerous currents in damp or wet ADSS cable or its equipment. | |
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