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Practice Sheet 2

The document summarizes several manufacturing processes problems involving determining required forces, dimensions, and process parameters: 1) A blanking die problem to determine punch and die dimensions and required force for stainless steel. 2) A compound die problem to determine punch and die sizes for blanking and punching aluminum alloy sheet. 3) An extrusion problem to determine force for extruding a brass billet. 4) A rolling problem to determine roll force and power for rolling a copper strip.

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GUNJAN KHULLAR
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89 views2 pages

Practice Sheet 2

The document summarizes several manufacturing processes problems involving determining required forces, dimensions, and process parameters: 1) A blanking die problem to determine punch and die dimensions and required force for stainless steel. 2) A compound die problem to determine punch and die sizes for blanking and punching aluminum alloy sheet. 3) An extrusion problem to determine force for extruding a brass billet. 4) A rolling problem to determine roll force and power for rolling a copper strip.

Uploaded by

GUNJAN KHULLAR
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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UTA026 Manufacturing Processes

1. A blanking die is to be designed to blank the part outline shown in Figure. The material is
4-mm thick stainless steel. Determine the dimensions of the blanking punch and the die
opening. Determine the blanking force required if the shear strength of the steel is 321
MPa. All dimensions are in mm.

2. A compound die will be used to blank and punch a washer out of 6061 aluminum alloy
sheet stock 3.50 mm thick. Dimensions (in mm) of the washer are shown in figure below.
Determine
(i) the punch and die sizes for the blanking operation and (ii) the punch and die
sizes for the punching operation.

20

50
3. A round billet made of 70-30 brass is extruded at a temperature of 675°C. The billet
diameter is 125mm and the diameter of the extrusion is 50mm. Calculate the extrusion
force required. Assume the extrusion constant to be 250 MPa.
4. An annealed copper strip 228mm wide and 25mm thick is rolled to a thickness of 20mm
in one pass. The roll radius is 300mm and the rolls rotate at 100 rpm. Calculate the roll
force and power required in this operation. Assume average flow stress of the material as
180 MPa.
5. Take two solid, cylindrical specimens of equal diameter (= 75 mm), but different heights
(100 mm and 150 mm), and compress them (frictionless) to the same 10% percentage
reduction in height. Calculate the final diameters for both the components.
6. A steel plate is rolled to reduce its thickness from 25 mm to 18 mm using a 2-Hi mill roll
with a roll diameter of 500 mm. Assuming the friction coefficient at roll-plate interface as
0.15, check whether it is possible to roll this plate in one pass. If it is not possible to roll in
one pass using this mill, you have an option to change the roll size. Calculate what should be
the size of the roll if this plate has to be rolled in one pass assuming the coefficient of friction
remains same as above. If the rolls rotate at 100 rpm, calculate the roll force and power
required in this operation. Assume the width the plate is 150 mm and the average flow stress
of the material as 180 MPa.

7. During spot welding of MS sheets 6mm thick, 2000A current is passed for 0.5µs. Sheet interface
resistance is 130Ώ and 40% of the heat generated is lost due to radiation and other losses. If
10,000J is the heat required to melt one gram of material melting, determine the size of the
nugget formed? Assume the nugget is spherical and density of steel is 7.8 g/cm 3.

8. During submerged arc welding with constant voltage characteristics curve being used for the
welding operation. If arc length changes from 3mm to 4mm, current drops by 200A. Open
circuit voltage is 80V. Find short circuit current. Also find welding voltage and current for 3.5
mm arc length. Arc voltage characteristic curve is v = 20+4l.

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