Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 16, Problem 37QLP
Through changes in clamping or die design, it is possible for a sheet metal to undergo a negative minor strain. Explain how this effect can be advantageous.
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5) A steel specimen of rectangular cross section with 120 mm width, 180 mm
thickness and 90 mm height was upset at room temperature by open-die forging to
a height of 55 mm. If the strength coefficient and strain hardening exponent of this
material were 1015 MPa and 0.17 respectively, the coefficient of friction is 0.2, and
assuming that the thickness would not change during forging; determine the
required upsetting force at the end of stroke.
What is K constant in sheet metal bending? How to calculate shear force and extrusions? Formulas?
4) Make a summary of the types of defects found in sheet-metal forming processes,
and include brief comments on the reason(s) for each defect.
Chapter 16 Solutions
Manufacturing Engineering & Technology
Ch. 16 - How does sheet-metal forming differ from rolling,...Ch. 16 - What causes burrs? How can they be reduced or...Ch. 16 - Prob. 3RQCh. 16 - Describe the difference between compound,...Ch. 16 - Describe the characteristics of sheet metals that...Ch. 16 - Describe the features of forming-limit diagrams...Ch. 16 - List the properties of materials that influence...Ch. 16 - Give one specific application for each of the...Ch. 16 - Why do tubes buckle when bent? What is the effect...Ch. 16 - Define normal anisotropy, and explain why it is...
Ch. 16 - Describe earing and why it occurs.Ch. 16 - What are the advantages of rubber forming? Which...Ch. 16 - Explain the difference between deep drawing and...Ch. 16 - How is roll forming fundamentally different from...Ch. 16 - What is nesting? What is its significance?Ch. 16 - Describe the differences between compound,...Ch. 16 - What is microforming?Ch. 16 - Explain the advantages of superplastic forming.Ch. 16 - What is hot stamping? For what materials is it...Ch. 16 - What is springback? What is negative springback?Ch. 16 - Explain the differences that you have observed...Ch. 16 - Take any three topics from Chapter 2, and, with...Ch. 16 - Do the same as for Problem 16.22, but for Chapter...Ch. 16 - Identify the material and process variables that...Ch. 16 - Explain why springback in bending depends on yield...Ch. 16 - Explain why cupping tests may not predict well the...Ch. 16 - Identify the factors that influence the...Ch. 16 - Why are the beads in Fig. 16.36b placed in those...Ch. 16 - A general rule for dimensional relationships for...Ch. 16 - Section 16.2 stated that the punch stripping force...Ch. 16 - Is it possible to have ironing take place in an...Ch. 16 - Note the roughness of the periphery of the flanged...Ch. 16 - What recommendations would you make in order to...Ch. 16 - It has been stated that the quality of the sheared...Ch. 16 - Give several specific examples from this chapter...Ch. 16 - As you can see, some of the operations described...Ch. 16 - Through changes in clamping or die design, it is...Ch. 16 - How would you produce the part shown in Fig....Ch. 16 - It has been stated that the thicker the sheet...Ch. 16 - Prob. 41QTPCh. 16 - Calculate the value of R in Problem 16.41. Will...Ch. 16 - Estimate the limiting drawing ratio for the...Ch. 16 - Using Eq. (16.15) and the K value for TNT, plot...Ch. 16 - Section 16.5 states that the k values in bend...Ch. 16 - For explosive forming, calculate the peak pressure...Ch. 16 - Measure the respective areas of the solid outlines...Ch. 16 - Plot Eq. (16.6) in terms of the elastic modulus,...Ch. 16 - What is the minimum bend radius for a 1.0-mm-thick...Ch. 16 - Survey the technical literature and explain the...Ch. 16 - Using the data in Table 16.3 and referring to Eq....Ch. 16 - What is the force required to punch a square hole...Ch. 16 - In Case Study 16.2, it was stated that the reason...Ch. 16 - A cup is being drawn from a sheet metal that has a...Ch. 16 - Prob. 55QTPCh. 16 - Figure P16.57 shows a parabolic profile that will...Ch. 16 - Prob. 59SDPCh. 16 - Consider several shapes to be blanked from a large...Ch. 16 - Prob. 61SDPCh. 16 - Many axisymmetric missile bodies are made by...Ch. 16 - Metal cans are either two-piece (in which the...Ch. 16 - The design shown in Fig. P16.65 is proposed for a...Ch. 16 - Suggest consumer-product designs that could...Ch. 16 - How would you produce the part shown in Fig. 16.44...Ch. 16 - Using a ball-peen hammer, strike the surface of...Ch. 16 - Inspect a common paper punch and observe the shape...Ch. 16 - Obtain an aluminum beverage can and slit it in...Ch. 16 - Prob. 71SDPCh. 16 - Prob. 73SDPCh. 16 - On the basis of experiments, it has been suggested...Ch. 16 - Design a box that will contain a 4-in. 6-in. ...Ch. 16 - Repeat Problem 16.77, but design the box from a...
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- Explain the basic operation of closed-die forging. Use sketches to assist the explanation.arrow_forwardCould you please solve this problem for mearrow_forwardA rectangufar workpiece has the following original dimensions: 2a = 120 mm, h = 40 mm and width = 25 mm (see Fig. 6.5). The metal has a strength coefficient of 530 MPa and a strain hardening exponent of 0.26. It is being forged in-plane strain with u = 0.25. Calculate the force required at a reduction of 25%. Use the average- Question 2 Not yet answered Marked out of 5 pressure formula. P Flag questionarrow_forward
- One way to define forging procedures is by the extent to which the work is constrained in the die. Explain this classification system by identifying the three primary classes.arrow_forwardA billet 100 mm long and 40 mm diameter is to be extruded in a direct extrusion with final diameter of product 32 mm. The semi die angle is 60°. The work metal has a strength coefficient 500 Map, and strain hardening 0.2 use the Johnson formula with a=0.8 and b=1.45 to estimate the extrusion strain. Determine the pressure applied to the end of the billet as the ram moves forward.arrow_forwardAn open die forging operation is performed to produce a steel cylinder with a diameter of 9.7mm and a height of 1.7mm. The strength coefficient for this steel is 500MPA, and the strain hardening exponent is 0.25. Coefficient of friction at the die-work interface is 0.12. The initial stock of raw material has a diameter of 5mm. (a) What height/length of stock is needed to provide sufficient volume of material for this forging operation? (b) Compute the maximum force that the punch must apply to form the head in this open- die operation.arrow_forward
- Answer it fast pleasearrow_forwardA cylindrical part is warm upset forged in an open die. The initial diameter is 50 mm and the initial height is 40 mm. The height after forging is 30 mm. The coefficient of friction at the die-work interface is 0.25. The yield strength of the work material is 285 MPa, and its flow curve is defined by a strength coefficient of 600 MPa and a strain-hardening exponent of 0.12. Calculate the strain at yield point.arrow_forwardkindly help me with this problem choose the correct answerarrow_forward
- What is K-constant when it comes to sheet metal bending? How do you measure it and what's the formula?arrow_forwardExplain briefly the relationship between the load-stroke in open die forging as illustrated in the figures bellow. Take in consideration the effect of coefficient of friction.arrow_forwardA steel billet with a rectangular cross section is being forged using a die with a width of 84.5 mm. The billet has an original thickness of 46.0 mm and a width of 273 mm. The billet is upset to a thickness of 28.0 mm and the coefficient of friction for the workpiece-die interface is 0.234. Take the strength coefficient (K) as 526 MPa and the strain-hardening exponent (n) as 0.225. a) Determine the maximum die pressure (do not use average pressure formula). Expected answer: 1050 MPa b) Determine the required forging force (use average pressure). Expected answer: 16200000 Narrow_forward
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