Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 16, Problem 39QLP
It has been stated that the thicker the sheet metal, the higher is the curve in the forming-limit diagram. Explain why.
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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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- 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.arrow_forwardA blank workpiece with 200 mm diameter is to be blanked from 3.2- mm-thick half-hard stainless steel (ultimate tensile strength of 650 MPa). Find (a) the diameters of blank die and punch, and (b) blanking force.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
- Explain the basic operation of closed-die forging. Use sketches to assist the explanation.arrow_forwardThe figure below shows a symmetric plane-strain upsetting process. The process may also be thought of as a form of side extrusion. Observations show that the deformation is confined to two shear planes, each one being analogous to that seen in plane-strain cutting. You may assume that there is no friction between the work material and the tool/die walls; the uniaxial yield strength of the material is σy and is independent of strain rate and temperature, and the material behaves as a rigid plastic solid. a) Calculate the pressure (p) required for the upsetting process in terms of σy. b) If friction existed at the die walls and the frictional work (energy) dissipation was 30% of the energy required for shape change alone (part (a) above), then what would be the pressure (p)?arrow_forwardOne 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_forward
- Explain why and how various factors influence springback in bending of sheet metals.arrow_forwardA 10 mm thick plate is rolled to 7 mm thick in a rolling mill using 1000 mm diameter rigid rolls. The neutral point is located at an angle of 0.3 times the bite angle from the exit. What will be the thickness of the plate at the neutral point.arrow_forwardA 300 mm thick slab is being cold rolled using roll of 600 mm diameter. If the coefficient of friction is 0.08, the maximum possible reduction is,arrow_forward
- A spool of wire has a starting diameter of 2.5 mm. It is drawn through a die with an opening that is 2.1 mm at a speed of 0.3 m/s. The worked metal has a strength coefficient of 450 MPa and a strain-hardening coefficient of 0.26. Assume the drawing is performed at room temperature and that the frictional and redundant work together constitute 35% of the ideal work of deformation. Calculate the power required to carry out the operationarrow_forwardA upset forging operation is performed in an open die. The initial size of the workpart is: Do = 63 mm, and ho = 100 mm. The part is upset to a diameter = 70 mm. The work metal has a flow curve with strength coefficient = 600 MPa and strain hardening exponent= 0.22. Coefficient of friction at the die-work interface = 0.40. Determine (a) final height of the part, and (b) maximum force in the operation.arrow_forwardExplain the basic operation of open-die forging. Use sketches to assist the explanation.arrow_forward
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