Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 16, Problem 59SDP
To determine
Survey from some of the sheet metal products in your home or in an automobile, and discuss the process or combination of processes by which you think they were made.
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Explain in your own words how the stress test (performance test) is applied to the patient turning apparatus shown in the figure, and guess how the expected result will be. The main part of the product consists of a polyurethane sponge. Stain-proof upholstery fabric will be used as the outer surface material. In addition, there are heating pads working with the logic of electric blankets in this apparatus, please answer by taking these into account when answering.
please 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.
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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- A 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_forward1 What is the difference between open-die and closed-die forging? Give an example of a metal product produced by each process.arrow_forward2) Assume that you are carrying out a sheet forming operation and you find that the material is not sufficiently ductile. Make suggestions to improve its ductility.arrow_forward
- 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.arrow_forwardPlease give answers to both of these parts, thanks (a) Manufacturing is “ the transformation of materials into items of greater value by means of one or more processing and/or assembly operations”. Elaborate on this statement (b) It is not possible to conduct a rolling process without friction. Explain this statement.arrow_forward• In a sheet metal forming press the shape to be formed is hemispherical cup of radius 15 cm in 2mm thick mild steel sheet. The force required to deform sheet is 8 kN. The forming hammer should approach job from a distance of 30 cm. The production rate required is 240 components/hr. Calculate and suggest the following specifications of the various hydraulic components used: a) Hydraulic cylinder (bore & length) b) Pump pressure and flow rate c) Electric motor HP considering 75% pump efficiency d) Reservoir size e) Size of pump inlet and discharge tubingarrow_forward
- How can we possibly measure the drawability of sheet metal ?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_forwardA flat metal sheet is bent into V shape using appropriate punch and die, both having included angle of 45 degrees. After the process it is found that the included angle of sheet is greater than 45 degrees. This phenomenon is known as: A-positive spring back C-plasticity V die of 0 = 45° 0>45° After process B-Negative spring back. D- Insufficient data.arrow_forward
- Circles of a metal are being punched that will be later stamped into coins. The metal has a shear strength of 32,575 psi. The sheets are 2.1 mm thick. The coin blanks are to be 16.5 mm in diameter. If sheet of metal is expected to produce 50 coin blanks, how much force is required to punch the sheets?arrow_forward1. In the manufacture of automotive-body panels from carbon-steel sheet, stretcher strains (Lueders bands) are observed, which detrimentally affect surface finish. How can stretcher strains be eliminated? Explain with appropriate sketches. Also discuss how wrinkles in a deep drawing operation can be eliminated.arrow_forwardDo you expect a material's stiffness to increase or decrease if there is more than one deformation mechanism occuring? Why?arrow_forward
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