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Solving session 4

The document contains solutions to various problems related to metal forming processes, including calculations for clearance settings, punch and die sizes, force requirements for blanking and punching operations, and feasibility assessments for deep drawing operations. Key calculations involve determining dimensions based on material thickness, tensile strength, and other parameters. The document also discusses the implications of different blank sizes on the feasibility of producing specific shapes.

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nashimounir
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15 views

Solving session 4

The document contains solutions to various problems related to metal forming processes, including calculations for clearance settings, punch and die sizes, force requirements for blanking and punching operations, and feasibility assessments for deep drawing operations. Key calculations involve determining dimensions based on material thickness, tensile strength, and other parameters. The document also discusses the implications of different blank sizes on the feasibility of producing specific shapes.

Uploaded by

nashimounir
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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Solving session 4

Chapters 16
Problem 16.1
• A power shears is used to cut soft cold-rolled steel that is 3.2 mm
thick.
• At what clearance should the shears be set to produce an optimum
cut?
Problem 16.1 – Solution
c = Act

c = Act = 0.060(3.2) = 0.192 mm


Problem 16.2
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 the punch and die sizes for (a) the blanking operation, and
(b) the punching operation.
Problem 16.2 – Solution
From Table 16.1, Ac = 0.060.
Thus, c = 0.060(3.2) = 0.192 mm
Problem 16.2 – Solution contd.
(a) Blanking punch diameter = Db - 2c = 25.0 - 2(0.192) = 24.62 mm
Blanking die diameter = Db = 25.00 mm

(b) Punching punch diameter = Dh = 12.00 mm


Punching die diameter = Dh + 2c = 12.0 + 2(0.192) = 12.38 mm
Problem 16.3
A blanking die must be designed to
blank the part shown in the figure.

The material is 4-mm-thick stainless


steel (half hard).

Determine the dimensions of the


blanking punch and the die opening.
Problem 16.3 – Solution
From Table 16.1, Ac = 0.075.
Thus, c = 0.075(4.0) = 0.30 mm

Blanking die: dimensions are the same as for the part in Figure.

Blanking punch: 85 mm length dimension = 85 - 2(0.3) = 84.4 mm


50 mm width dimension = 50 - 2(0.3) = 49.4 mm
Top and bottom 25 mm extension widths = 25 - 2(0.3) = 24.4 mm
The 25 mm inset dimension remains the same.
Problem 16.2: A compound die is used to blank and punch a
large washer out of 6061ST aluminum alloy sheet stock 3.2 mm
Problem 16.4 thick. The outside diameter of the washer is 25.0 mm, and the
inside diameter is 12.0 mm.

Determine the minimum force capacity press to perform the blanking and
punching operation in Problem 16.2 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 sheet metal has a tensile strength = 350 MPa.


Problem 16.4 – Solution
(a) F = 0.7(TS)tL

t =3.2 mm from Problem 16.3.

L = 25 + 12 = 37 = 116.2 mm

F = 0.7(350)(3.2)(116.2) = 91,101 N
Problem 16.4 – Solution contd.
(b) Longest length will determine the minimum tonnage press required,
if punching and blanking are performed separately.

For the punching length of cut, L= 12π, and for the blanking length of
cut, L=25π = 78.5 mm.

Thus use the blanking operation to determine press capacity.

F = 0.7(350)(3.2)(78.5) = 61,575 N
Problem 16.5
Determine the tonnage requirement for the blanking operation in Problem
16.3, given that the stainless steel has a yield strength = 275 MPa, shear
strength = 450 MPa, and tensile strength = 650 MPa.
Problem 16.5 – Solution
F = StL

t = 4 mm from Problem 16.3.

L = 85 + 50 + 25 + 25 + 35 + 25 + 25 + 50 = 320 mm

F = 450(4.0)(320) = 576,000 N
Problem 16.7
A bending operation is to be
performed on 5.00 mm thick cold-
rolled steel as shown in figure.

Determine the blank size required.


Bending equations
Bend Allowance:

Spring back:
Bending equations contd.
Bending force:
Problem 16.7 – Solution
From drawing: ’ = 40, R = 8.50 mm
 = 180 - ’ = 140
Ab = 2(/360)(R + Kbat)
R/t = (8.5)/(5.00) = 1.7, which is less than 2.0; therefore, Kba = 0.333
Ab = 2(140/360)(8.5 + 0.33 x 5.0) = 24.80 mm

Dimensions of starting blank: w = 35 mm,


L = 58 + 24.80 + 46.5 = 129.30 mm
Problem 16.10
Determine the bending force in Problem 16.7 if the bend is performed in a
V-die with a die opening dimension = 40 mm. The steel has a tensile
strength = 350 MPa and shear strength = 250 MPa

Solution:
For V-bending, Kbf = 1.33.
F = Kbf(TS)wt2/D = 1.33(350)(35)(5.0)2/40 = 10,183 N
Problem 16.11
Solve Problem 16.10 except that the operation is performed using a
wiping die with die opening dimension = 28 mm.

Solution:
For edge-bending in a wiping die, Kbf = 0.33.
F = Kbf(TS)wt2/D = 0.33(350)(35)(5.0)2/28 = 3,609 N
Problem 16.14
A cylindrical cup is produced in a deep drawing operation.
The cup height = 75 mm, and its inside diameter = 100 mm. Sheet-
metal thickness = 2 mm.

If the blank diameter = 225 mm, determine (a) drawing ratio, (b)
reduction, and (c) thickness-to-diameter ratio. (d) Is the operation
feasible?
Problem 16.14 – Solution
Solution:
(a) DR = Db/Dp = 225/100 = 2.25 >2
(b) r = (Db - Dp)/Db = (225 - 100)/225 = 0.555 = 55.5% >50%
(c) t/Db = 2/225 = 0.0089 = 0.89% <1%
(d) Feasibility? No! DR is too large (greater than 2.0), r is too large
(greater than 50%), and t/D is too small (less than 1%).
Problem 16.15 – Solution
Solve Problem 16.14, except that the starting blank size diameter = 175
mm.

Solution:
(a) DR = Db/Dp = 175/100 = 1.75 <2
(b) r = (Db - Dp)/Db = (175 - 100)/175 = 0.429 = 42.9% <50%
(c) t/Db = 2/175 = 0.0114 = 1.14% >1%
Problem 16.15 – Solution contd.
(d) Feasibility?
DR < 2.0, r < 50%, and t/D > 1%.

However, the operation is not feasible because the 175 mm diameter


blank size does not provide sufficient metal to draw a 75 mm cup
height. The actual cup height possible with a 175 mm diameter blank
can be determined by comparing surface areas (one side only for
convenience) between the cup and the starting blank.
Problem 16.15 – Solution contd.
Blank area = D2/4 = (175)2/4 = 24,053 mm2.
To compute the cup surface area, let us divide the cup into two sections: (1)
walls, and (2) base, assuming the corner radius on the punch has a negligible
effect in our calculations and there is no earing of the cup.
Thus, Cup area = Dph + Dp2/4 = 100h + (100)2/4 = 100h + 2500 =
314.16h + 7854.
Set surface area of cup = surface are of starting blank:
314.16h + 7854= 24,053
314.16h = 16,199
• h = 51.56 mm. This is less than the specified 75 mm height.

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