By an engineer with decades of practical manufacturing experience, this book is a complete modern guide to sheet metal forming processes and die design - still the most commonly used methodology for the mass-production manufacture of aircraft, automobiles, and complex high-precision parts. It illustrates several different approaches to this intricate field by taking the reader through the "hows" and "whys" of product analysis, as well as the techniques for blanking, punching, bending, deep drawing, stretching, material economy, strip design, movement of metal during stamping, and tooling. While concentrating on simple, applicable engineering methods rather than complex numerical techniques, this practical reference makes it easier for readers to understand the subject by using numerous illustrations, tables, and charts. Emphasizes the influence of materials as an aid to understanding manufacturing processes and operations. Features the essential mathematical formulas and calculations needed for various die operations and performance evaluation. Shows the comparative advantages and liabilities for each manufacturing process and operation. Offers a complete picture of the knowledge and skills needed for the effective design of dies for sheet-metal forming processes highlighted with illustrative examples. Provides properties and typical applications of selected tool and die materials for various die parts.

Sheet Metal Technology is written in Dave’s unique style with the beginner or vocational student in mind as he demonstrates how a product idea is conceived, developed and then produced by a single craftsman with basic tools. Subjects covered are safety in the shop, use of tools, layout and pattern development, various ways of forming and joining metal along with edging methods, corner systems and panel reinforcement. You will be introduced to the basic sheet metal shop where you will learn about various methods of forming sheet metal and in some instances even constructing your own tools including a rather unique and functional 24" sheet metal brake constructed of hardwood. The final chapter opens with a mass production operation set up to demonstrate the efficiency and economy of modern industrial technology. Then further projects are progressively introduced as skill is acquired. Such projects as a dustpan for the shop, a handy tool tote tray as well as plans for single and double hinge tool boxes. By this time you are an advanced student and ready to construct the unique portable charcoal grill and the impressive three drawer tool chest from the plans provided. Dave Gingery brings it all within your grasp and you will be amazed at what can be produced with tin snips, standard measuring tools and a 24" sheet metal brake.

"How to: Extend a tank -- Shrink & stretch -- Modify & mount a fender -- Make a fender from scratch -- Weld steel & aluminum - gas/TIG."--cover.

Dear Readers, Thanks for making my other books #1 best sellers on Amazon! This book is written with more than 1000 years of experience... I mean it... I have many friends in my personal and professional networks who contributed to this book. They earned huge experience by working at world's largest companies. If we add their experiences then it would easily cross 1000 years. That's the reason I took long time to come up with this book, to respect their guidance and to provide maximum benefits to you. In this book, you will learn about the latest industrial technologies, also you will get exposures to very interesting & important future technologies, like: Impact of Electric Vehicle (EV) on sheet metal industry Bionic design for sheet metals - popular in aerospace and coming soon to automotive With help of more than 436 figures , I have tried to bring almost everything I was advised to bring for you. You can test your learning with 290 MCQ. A quick glimpse will get you an idea about the quality and comprehensiveness of the book. I am sure, this book will become an asset for you, and you would read it multiple times to enjoy, comprehend the information, knowledge and industry insights provided in this book. Have a wonderful learning experience!Ashok Kumar What should you expect from this book... 1. Introduction- Manufacturing & applications2. Cutting sheet metals- Cutting technologies (shear, sawing, laser, plasma, & waterjet)- Types of cutting (slitting, cutoff & parting, punching & blanking, notching, saving, & lancing)- Deciding cut sequence3. Forming sheet metals- Bending (air bending, spring back, neutral axis & K-factor, offset, bottoming, 3-point, edge/wipe, roll, elastomer/geurin, joggle, folding, flanging & flaring)- Air bend force chart- Other forming processes (Extrusion, Stamping, Stretching, Drawing, Ironing, Embossing, Coining, SPF, EXF, MPF, EHF, Hydro, RPF, Roll, Peen, & Spinning)4. Joining sheet metals- Electric arc welding (MAW, GMAW/MIG, GTAW/TIG, PAW, CAW, & SAW)- Electric resistance welding (spot seam, & projection)- Gas flame welding- Laser beam welding (LBW)- Electron beam welding (EBW)- Solid state friction stir & ultrasound welding- Weld design (butt, lap, corner, tee, & plug)- Brazing & soldering- Riveting- Fasteners (bolts, nuts, screws, tacks)- Clinching- Seaming- Adhesive bonding5. Designing sheet metal products- Sheet metal designing (bend radius, bend relief, hole/slot size & location, extruded hole, curl, hem, notches & tabs, fillets, countersink holes, lance/louver design, emboss/bed/rib design)- Advanced design concepts (edge, flange, gussets, ribs, chamfer, wrapped corners, collars, coining & embossing)- Material selection (ferritic/austenitic/martensitic/duplex stainless steels, drawing steel, HSS, 1st, 2nd & 3rd generations AHSS, UHSS, & PHS)- Aluminium sheets in automotive-BIW- Sheet thickness & tolerances- Design for manufacturing-DFM & product life cycle5. Finishing sheet metal products- Deburring- Sand blasting- Plating (anodizing, zinc plating/galvanizing, nickel, zinc-nickel, chrome, tin, designing for plating)- Coating (chromate conversion, passivation, powder coating)- Automotive examples7. Drafting of sheet metal parts- Drafting rules- Band lines, direction, & radius- Hole/bend charts- Flat pattern layout- Welding symbols- Notes & other sectionsAppendices - Future ahead Bionic design Electric vehicles Enjoy the core of engineering!