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ISE386 Assignment 1 Solution - Final

This document provides the solution to an exercise on sheet metal forming part design. It includes: 1) Calculations to determine the diameter of a cup blank given the cup dimensions and assumptions of uniform thickness and unchanged volume. 2) The drawing force required is calculated as 190 kN. 3) The piercing and blanking operations are identified to make a T-shaped part from a strip, and the total cutting force is calculated as 57.6 kN. 4) Comments note that a hole diameter is too small and distance between holes too close to meet manufacturing standards.

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217 views2 pages

ISE386 Assignment 1 Solution - Final

This document provides the solution to an exercise on sheet metal forming part design. It includes: 1) Calculations to determine the diameter of a cup blank given the cup dimensions and assumptions of uniform thickness and unchanged volume. 2) The drawing force required is calculated as 190 kN. 3) The piercing and blanking operations are identified to make a T-shaped part from a strip, and the total cutting force is calculated as 57.6 kN. 4) Comments note that a hole diameter is too small and distance between holes too close to meet manufacturing standards.

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吳心
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© © All Rights Reserved
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ISE386 Integrated Design for Manufacture

Exercise 1: Sheet Metal Forming Part Design

Solution
Question 1

(a) There are 2 assumptions:


(1) The volume of the shell blank does not change after forming a cup.
(2) The thickness of the cup does not change and is still uniform throughout.

The surface area of the cup material = The surface area of cylindrical wall + the surface area of base.
πDo2/4 = πdh + πd2/4
2
Do /4 = dh + d2/4
Do2 = 4dh +d2
Do = √4dh + d2

(b) The shell blank diameter is given by Do = √4dh + d2 ,


Do = �4 × 98 × 41 + 982
Do = √16072 + 9604
Do = √25676
Do = 𝟏𝟏𝟏𝟏𝟏𝟏. 𝟐𝟐 𝐦𝐦𝐦𝐦

160.2
Check 98 = 1.64, which is < m1 of 1.75,
The reduction is within the allowable safety limit, it can be drawn from 160.2 to 98 mm diameter
directly.

The drawing force:


D
F = πdtσt � do − c� Where F is the drawing force in N.
160.2
F = π × 98 × 2 × 320 × � − 0.675�
98
= π × 62720 × (1.64 − 0.675)
= 196940.8 × 0.965 = 190047.87N
= 190 kN

1
Question 2

(a) Piercing and blanking


The operation of piercing the three holes (one Ø1.8 and two Ø8) on the GS strip with a width larger
than 60 mm.
The operation of blanking the outer Tee-shaped profile.

Step 1: piercing the three holes Step 2: blanking the outer profile

(b) Total cutting force for the outer Tee-shaped profile


= Cutting length × material shear strength × material thickness
Per the discussion in the class/tutorial, material shear strength=0.8×its tensile strength
(i.e. τ=0.8×σ)
= Cutting length × (0.8 × material tensile strength) × material thickness
= (20 × 3 + 60 × 3) × (0.8 × 150) × 2
= (240)(120)(2)
= 57600 N
= 57.6 kN

(c)
(i) Comment on the hole dimension Ø1.8 mm
The diameter to thickness ratio is too small, the current value is 1.8/2 = 0.9. It should be equal to or
larger than 1. (or The hole dimeter of Ø1.8 is small than 2t.) It is suggested that that hole diameter
should be changed to equal or larger than 2t, i.e., ≥ Ø4 mm.

(ii) Comment on the distance apart of holes with Ø8 mm from their edges.
The current distance apart of holes with Ø8 mm from the edges of the Tee-profile is margin, just 2 mm
(i.e, 1t). It is recommended that the minimum distance between the holes in the component should be at
least 1.2 times the material thickness, i.e. 2.4 mm (i.e., 1.2t).

-End-

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