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Assignment 1 ENG 173 METAL FORMING

This document discusses various metal forming processes including blanking, piercing, deep drawing, redrawing, and wire drawing. It provides definitions, explanations, and calculations related to factors that influence these processes like flow curves, strippers, die types, forces, and reductions. The document also asks the reader to calculate blank and part dimensions, drawing requirements, forces, and optimal die angles for given metal sheet and wire forming scenarios.

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60 views2 pages

Assignment 1 ENG 173 METAL FORMING

This document discusses various metal forming processes including blanking, piercing, deep drawing, redrawing, and wire drawing. It provides definitions, explanations, and calculations related to factors that influence these processes like flow curves, strippers, die types, forces, and reductions. The document also asks the reader to calculate blank and part dimensions, drawing requirements, forces, and optimal die angles for given metal sheet and wire forming scenarios.

Uploaded by

toursena44
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Assignment 1 METAL FORMING

1. Define the followings:


i- Isothermal forming ii- Blanking and piercing iii- Warm forming
2. What is flow curve? Discuss the effect of the following parameters on the flow
curve:
i- The specimen temperature ii- Strain rate
3. What is stripper? Explain with sketches the different types of strippers.
4. list with simple sketches the different types of sheet metal dies.
5. What is the difference between compound and progressive dies used in sheet metal
working?
6. List the advantages and disadvantages of transfer die used in sheet metal working.
7. Draw sketches showing the difference between fine-edge blanking and fine edge
piercing process and then mention the function of impingement ring and counter
holder in this process.
8. List with the aid of a sketch the defects of blanked parts in blanking operations.
9. In blanking and piercing operations, on what factor does the clearance depends.
10. What are the press and tool requirements for blanking and piercing operations?
11. In a particular blanking and piercing operations, 30 mm blank (or hole) are to be
punched in a brass sheet 2 mm thick. The maximum shear strength of the sheet
may be taken as 190 MPa. Calculate the punch and die size in both blanking and
piercing operations as well as the max shearing force, press capacity and stripping
force (take K = 0.02 kN/mm2).
12. Illustrate the followings:
i- Fine-edge Piercing ii- Deep drawing iii- HDD
13. A circular cup is to be drawn from a steel blank 1 mm thick. The outside diameter
of the cup is 81 mm; respectively. The cup height is 90 mm. Find the blank
diameter required to draw the cup.
14. Explain with sketches the difference between direct and reverse redrawing then
mention the advantages of reverse redrawing.
15. Draw a sketch showing the hydromechanical deep drawing. List the advantages
of this technique and for what types of metals is it suited.
16. List the possible reasons for fracture the cup bottom during deep drawing.
17. A circular cup is to be drawn from a steel blank. The outside and inside diameters
of the cup are 81 and 79 mm. The cup height is 120 mm. Find out:
i- The blank diameter required to draw the cup,
ii- The number of redraws needed, if the max ratio for drawing is 2 and that for
redrawing is 1.25,
18. Sketch the die used for wire drawing showing its main parts then mention the
effect of the die angle on friction force and internal shearing force and explain
how you can get the optimum die angle.
19. A steel wire 5.5 mm diameter is drawn to 4.5 mm using a die whose angle is 6º.
The coefficient of friction at the die working surface is 0.1. Calculate the
percentage reduction in the drawing force if a die with an optimum angle was used
20. A steel wire 6.5 mm diameter is drawn to 5.7 mm using a die whose angle is 8º.
The coefficient of friction at the die working surface is 0.1. The wire entering the
die has been subjected to a logarithmic strain = 0.25.
The flow curve is given by: σf = 670 φ0.24 [N/mm2], Find out:
i- The total drawing force. If the ultimate tensile strength of the sheet material is
σult. = 400 MPa, is the operation successful?
ii- How much of this force is required to overcome friction force?
iii- How much of this force is required to overcome internal shearing force?
iv- What is the optimum die angle for the given working conditions?
v- Calculate the percentage reduction in the drawing force if a die with an
optimum angle was used.
vi- Compare friction force and internal shearing force when the die angle is 8º and
when it is optimum.
21. Illustrate the followings:
i- Wire drawing ii- Bar drawing
22. List with sketches the different types of tube drawing and mention the application
of each method.

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