HW1
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peer highwayDeadline: 17/12/2021
1) 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 the minimum tonnage press to perform the blanking and
punching operation. The aluminum sheet metal has a tensile strength = 310 MPa, a strength
coefficient of 350 MPa, and a strain-hardening exponent of 0.12.
(a) Assume that blanking and punching occur simultaneously.
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(b) Assume the punches are staggered so that punching occurs first, then blanking.
2) A 300 mm wide strip 30 mm thick is fed through a double stage rolling process. The rollers
diameter is given in the figure. The draft value is same for two stages. The exit strip thickness is
24 mm. the work material has flow curve defined by K=275 MPa and n=0.12 and friction
coefficient is 0.15 for all rollers. Calculate the rolling force for each stage (F1 and F2).
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F1
F2
R1=300 mm
R2=250 mm
30mm 24mm
(1) (2)
3) The cutting conditions for a turning process are as follows:
Depth of cut: d=2 mm , Feed: f=0.2 mm/rev, Rotational speed of workpiece: N=350 rpm , Initial
dimension of workpiece: Do=100 mm, Length of workpiece: L=100 mm
Calculate the followings:
a) Cutting speed
b) Material removal rate
c) Machining time
4) Estimate the maximum bending force required for a 3 mm thick and 300 mm wide
Ti5Al2.5Sn titanium alloy in a V-die with a width of 150 mm. (UTS of material is 860 MPa,
assume bending die coefficient k = 1.2)
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5) A planned extrusion operation involves cold-rolled steel at 800ºC with an initial diameter of
100mm and a final diameter of 20mm. Two presses, one with a capacity of 20MN and the other
of 10MN, are available for this operation. https://starofgeeks.com
Obviously, the larger press requires greater care and more expensive tooling. Is the smaller press
sufficient for this operation? If not, what recommendations would you make to allow the use of
the smaller press.
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6) Calculate the force required in direct extrusion of 1100-O aluminium from a diameter of 60
mm to 20 mm Assume that the redundant work is 30% of the ideal work of deformation, and the
friction work is 25% of the total work of deformation. (K = 180 MPa, n = 0.20)
7) A round rod of annealed 70-30 brass is being drawn from a diameter of 10mm to 8mm at a
speed of 0.5m/s. Assume that the frictional and redundanthttps://starofgeeks.com
work together constitute 40% of the ideal work of deformation. Calculate the power required in
this operation and calculate the die pressure at the exit of the die (K=895MPa, n=0,49).
