- Mechanical
- Posts
- Optimizing sheet metal design - Part 2
Optimizing sheet metal design - Part 2
Plus: Mechanical engineering updates, hot jobs, best video games for engineers, and our Engineer of the Week is...
Ata Tanık
December 14, 2023
The Mechanical newsletter returns with the second and final instalment on the challenges of using sheet metal.
Previously, we explored how to achieve precision and excellence in sheet metal fabrication with a DFMA-backed guide to holes and bends. Today, we look at some of the other vital aspects of sheet metal design — curls, embossment, hems, and notches.
Also, in this week’s industry updates, we have news of a potential electric vehicle price drop, how scientists are using lessons from human physiology to harness wave energy, and the latest method to ensure the accuracy of optical designs.
Did a friend forward this e-mail to you?
INDUSTRY UPDATES
🚙 Automakers rush to deliver affordable EVs amidst Chinese competition
Companies worldwide are making efforts to reduce EV production costs due to competition from Chinese manufacturers.
💓 Beating heart-inspired wave energy converter now closer to deployment
Energy giant TotalEnergies partners with Swedish firm CorPower Ocean to explore the full potential of wave energy.
🔋 New study finds disposable e-cigarette batteries endure repeated use
Research reveals lithium-ion batteries could be recharged “sometimes many hundreds of times."
😖 Researchers craft stress-resistant materials
Purdue researchers create nature-inspired lightweight materials capable of withstanding high stress.
🧑🏼🏫 Closing the design-to-manufacturing gap for optical devices
New technique enables accuracy and efficiency and makes optical devices that are closer to design specifications.
SPOTLIGHT
Source: Flickr/Siemens PLM Software
Achieving precise sheet metal fabrication with DFMA
In the previous edition, we discussed a crucial process often underestimated by design engineers working on sheet metal products. We explored two pivotal DFMA considerations concerning holes and bends. Today, let’s talk about other crucial factors influencing sheet metal designs and highlight the tangible benefits of adhering to DFMA practices.
Curls and embossment:
Embosses are raised projections on the surface of stamped sheet metal parts. There is always a chance of deformation as embossment is restricted by the shape of the embossed feature and the malleability and thickness of the material. Common deformities include excessive thinning, stretching, and metal fracturing due to high tension. To overcome these issues, a general DFMA rule is to keep the depth of an embossment not more than three times the material thickness.
Curling is the process of giving a hollow circular roll at the edge of a sheet metal part. This makes the component or sheet safe for handling by removing sharp borders and adding strength to the edges. The size of holes located near or interacting with the curled edge should be at least the radius of the curl plus the material thickness from the curl feature. Bends nearby should be the radius of the curl plus six times the material thickness from the curl feature.
Hems and notches:
Folding the metal back on itself and creating hems – open or teardrop-shaped – helps strengthen the edges and make the sheet safer to handle. Hems are also helpful in doubling the thickness in specific areas of the sheet requiring increased support. Plus, they can also hide imperfections. The inside diameter of teardrop hems should be equivalent to material thickness. On the other hand, the bends in open hems will lose their roundness if the inside diameter is greater than the sheet thickness. The minimum distance between the inside and outside edge for the surrounding bends should be five times the material thickness, plus the bend radius and the hem radius combined.
The notching process involves removing a portion of a metal sheet or part from its outside edge. A notch should be placed at an appropriate distance from the bends after considering sheet thickness, as a metal sheet can distort if the distance between notches and bends is too small. The DFMA practice suggests that the notch width should be more than 1.5 times the material thickness, while the length can exceed up to 5 times the thickness.
The DFMA factors discussed here can be a good start to designing sheet metal products that are easier to fabricate. But there’s more to it. With the right design strategy, it’s also possible to minimize the number of parts and make the assembly process much easier. We’ll explore more about this strategy in our next edition.
CAREER CORNER
In this section you’ll find the latest jobs as featured on:
jobs.interestingengineering.com
 | Senior Software Engineer at Piranha Games Remote - $95,000–$115,000 a year |
 | AWS Cloud Software Engineer at FIS Global Boston (US) |
 | Junior Research Engineer at ENSCO, Inc. & Analytics Pueblo (US) $61,396 - $82,000 a year |
 | Principal Software Engineer at Light & Wonder Las Vegas (US) |
 | Senior Analog Design Engineer at ASML San Jose (US) |
 | Systems Engineer at Capgemini Engineering Michigan (US) |
 | ISD Engineer III- Oracle Security Administrator at Navy Federal Credit Union Vienna (US) |
 | DevOps Engineer at Accenture Federal Services Fort Belvoir (US) |
 | Engineer of the WEEK1907 - 1966Sergei Korolev  Aircraft Engineer |
Sergei Korolev is the Soviet rocket engineer of the early Cold War and space race era who made the first human spaceflight possible. On several occasions, his achievements in rocket engineering won his country victory in the technological rivalry between the two world superpowers. Korolev was subjected to torture and imprisonment on false charges during Stalin’s reign, but in 1945, he was commissioned as an officer of the Red Army and given a Badge of Honor for his contribution to the war. As officer in charge of systems engineering for Soviet launch vehicles and spacecraft, Korolev oversaw the entire design and development process of highly successful spacecraft like Sputnik, Vostok, and Soyuz. However, as per Soviet policies, his name was shrouded in secrecy until he died in 1966. | |
MOVIE RECOMMENDATIONS FOR MECHANICAL ENGINEERS
🌪 Transcendence (2014)
This visually and intellectually stimulating movie, starring Johnny Depp, explores the synergy of technology and consciousness. The movie involves an ethical dilemma associated with pushing the boundaries of technology, while the visual effects give life to advanced laboratories and nanobot swarms.
🦾 Pacific Rim (2013)
The action-packed sci-fi features giant humanoid robots fighting colossal sea monsters from another realm to defend Earth. The structural intricacies and the biomechanical interface that allow humans to control these machines are elements that mechanical engineers may find exciting.
🌎 The Core (2003)
This crisis-themed movie takes place in a reality where the earth’s electromagnetic field collapses. A team of experts is charged to detonate nuclear devices to restart the core. Though the movie is not accurate from a scientific and engineering point of view, it offers an entertaining ride.
🦑 The Abyss (1989)
The Abyss features the story of deep-sea oil drillers helping the NAVY recover a lost nuclear submarine in the depths of the Caribbean. It explores themes like human relations, extraterrestrial encounters, and underwater technology.
🏍 The World’s Fastest Indian (2005)
Based on a true story and filled with inspiration, The World's Fastest Indian is about a New Zealand motorcycle racer, Burt Munro. He is determined to break the land speed record at the Bonneville Salt Flats in Utah, USA, with his highly upgraded 1920 Indian Scout motorcycle.
Here are the EVENTS you'll love:
Precision in Motion: Navigating the
World of Mechanical Engineering Innovations
Aug. 22 • 9 a.m. PT / noon ET
Designing Tomorrow: Insights for Engineers
Aug. 23 • 9 a.m. PT / noon ET
Merging Mechanics and Ingenuity: Webinar Series for
Mechanical Engineers
Aug. 22 • 10 a.m. PT / 1 p.m. ET
Spider-like robotic AI arms can be attached to and controlled by humans Remember Doctor Octopus and his robotic tentacles in the 2004 movie Spider-Man 2? A Japanese robotics company has engineered.
Spider-like robotic AI arms can be attached to and controlled by humans Remember Doctor Octopus and his robotic tentacles in the 2004 movie Spider-Man 2? A Japanese robotics company has engineered.
Spider-like robotic AI arms can be attached to and controlled by humans Remember Doctor Octopus and his robotic tentacles in the 2004 movie Spider-Man 2? A Japanese robotics company has engineered.
 | Written by KASHYAP VYAS Science & Technology Writer
|
what else?
🚨 For IE’s daily engineering, science & tech bulletin, subscribe to The Blueprint
🧑🏻🔧 For expert advice on engineering careers, subscribe to Engineer Pros
🔷 For all the week’s top engineering stories, subscribe to the Vital Component
🧠 New: To get the latest AI news every Monday, subscribe to AI Logs
🎬 For a weekly round-up of our best science, tech & engineering videos, subscribe to IE Originals
For our weekly premium newsletter and an ad-free experience, sign up for IE+
