Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 16, Problem 52QTP
What is the force required to punch a square hole 50 mm on each side in a 0.1-mm-thick 5052-O aluminum sheet by using flat dies? What would be your answer if beveled dies are used?
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A compound die will be used to blank and punch a large washer out of 6061ST aluminum alloy sheet stock 3.50 mm thick. The outside diameter of the washer is 50.0 mm and the inside diameter is 15.0 mm. Determine (a) the punch and die sizes for the blanking operation, and (b) the punch and die sizes for the punching operation
Vallue for allowance = 0.060
Question 5
5.1 Calculate the final bend radius for a 3 mm thick 6061 T6 aluminum plate that is formed
using a forming punch with an 8 mm radius, as shown in Figure 3.
R 8
Figure 3: Bend profile that is formed using a V-block die and a punch with a 8 mm
radius
5.2 Explain why there would be a difference between the initial and final bend radius during
the bending process and how this occurrence depends upon material properties, sheet
thickness and the bend radius.
A compound die is used to blank and punch a large washer out of 6061ST aluminum alloy sheet
stock 3.2 mm thick. The outside diameter of the washer is 25.0 mm, and the inside diameter is 12.0
mm. Determine (a) the punch and die sizes for the blanking and punching operations, (b) the force
required to perform the blanking and punching operation under the following conditions: (a) blanking
and punching occur simultaneously and (b) the punches are staggered so that punching occurs first,
then blanking. The aluminum has a tensile strength = 350 MPa.
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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- Correct and complete solution please don't copyarrow_forwardPlease answer all partsarrow_forwardManufacturer process A compound die will be used to blank and punch a large rectangle (90x150mm blank dimensions) out of 6061ST aluminum alloy sheet stock 3.5 mm thick. The diameter of inside hole is 25 mm. The aluminum sheet metal has a tensile strength = 310 MPa. Determine the minimum tonnage press (force) to perform the blanking and punching operation (1) assume that blanking and punching occur simultaneously and (2) assume that punching occurs first, then blanking. Take: Ac=0.06arrow_forward
- Explain 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_forwardplease answer to both of these parts of the question, thanks (a) Explain the advantage of corner radii of punch and die in Sheet Metal Drawing Process. (b) Explain the disadvantages of Tube Drawing process in which mandrel is not used.arrow_forwardA blanking operation is to be performed on 3.0 mm thick cold-rolled steel (half hard). The part is circular with diameter = 80.0 mm. Determine the appropriate punch and die sizes for this operation.arrow_forward
- 4- A round sheet metal slug produced in a hole punching operation will have the same diameter as which of the following? (a) die opening, or (b) punch. 5- proof ( el+ ɛ2+ ɛ3=D0) at constant volume 6- List three of the products produced on a rolling mill. 7- Identify the three basic types of sheet metal working operations. 8- Which of the following is typical of the work geometry in sheet metal processes? (a) high volume-to-area ratio, or (b) low volume-to-area ratioarrow_forwardA solid cylinder of diameter 100 mm and height 50 mm is forged between two frictionless flat dies to a height of 25 mm. What is the percentage change in diameter?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_forward
- A deep drawing operation for a cup is performed in which the inside diameter = 60 mm %3D and the height = 50 mm. The blank thickness = 3 mm, and %3D %3D the starting blank diameter = 108 mm. Punch and die radii = %3D 4 mm. Tensile strength = 400 MPa and yield strength = 180 %3D MPa for this sheet metal. Determine (a) drawing ratio, (b) reduction, (c) drawing force, and (d) blankholder force. *arrow_forwardA 1-in diameter hole is to be punched through a 1/8-in thick annealed titanium-alloy Ti-6Al-4V (grade 5, annealed) sheet at room temperature. Estimate the force required for the punching operation. Show your work and list any values you reference/use. Hint: Use the equation F=T*L*Shear Strengtharrow_forward4. What are the advantages and limitations of using die inserts?arrow_forward
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