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Determine the minimum tonnage press to perform the blanking and punching operation in Problem 20.3. 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. (b) Assume the punches are staggered so that punching occurs first, then blanking
Determine the blanking force required in Problem 20.2, if the shear strength of the steel = 325 MPa and the tensile strength is 450 MPa.
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A blanking die is to be designed to blank the part outline shown in Figure P20.4. The material is 4 mm thick stainless steel (half hard). Determine the dimensions of the blanking punch and the die opening.
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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 (a) the punch and die sizes for the blanking operation, and (b) the punch and die sizes for the punching operation.
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A blanking operation is to be performed on 2.0 mm thick cold-rolled steel (half hard). The part is circular with diameter = 75.0 mm. Determine the appropriate punch and die sizes for this operation
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A power shears is used to cut soft cold-rolled steel that is 4.75 mm thick. At what clearance should the shears be set to yield an optimum cut?
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There are 21 correct answers in the following multiple choice questions (some questions have multiple answers that are correct). To attain a perfect score on the quiz, all correct answers must be given. Each correct answer is worth 1 point. Each omitted answer or wrong answer reduces the score by 1 point, and each additional answer beyond the correct number of answers reduces the score by 1 point. Percentage score on the quiz is based on the total number of correct answers.
\r\n20.1 Most sheet metalworking operations are performed as which one of the following: (a) cold working, (b) hot working, or (c) warm working?
\r\n20.2 In a sheet-metal-cutting operation used to produce a flat part with a hole in the center, the part itself is called a blank, and the scrap piece that was cut out to make the hole is called a slug: (a) true or (b) false?
\r\n20.3 As sheet-metal stock hardness increases in a blanking operation, the clearance between punch and die should be (a) decreased, (b) increased, or (c) remain the same?
\r\n20.4 A circular sheet-metal slug produced in a hole punching operation will have the same diameter as (a) the die opening or (b) the punch?
\r\n20.5 The cutting force in a sheet-metal blanking operation depends on which mechanical property of the metal (one correct answer): (a) compressive strength, (b) modulus of elasticity, (c) shear strength, (d) strain rate, (e) tensile strength, or (f) yield strength?
\r\n20.6 Which of the following descriptions applies to a V-bending operation as compared to an edgebending operation (two best answers): (a) costly tooling, (b) inexpensive tooling, (c) limited to 90° bends or less, (d) used for high production, (e) used for low production, and (f) uses a pressure pad to hold down the sheet metal?
\r\n20.7 Sheet-metal bending involves which of the following stresses and strains (two correct answers): (a) compressive, (b) shear, and (c) tensile?
\r\n20.8 Which one of the following is the best definition of bend allowance: (a) amount by which the die is larger than the punch, (b) amount of elastic recovery experienced by the metal after bending, (c) safety factor used in calculating bending force, or (d) length before bending of the straight sheetmetal section to be bent?
\r\n20.9 Springback in a sheet-metal-bending operation is the result of which one of the following: (a) elastic modulus of the metal, (b) elastic recovery of the metal, (c) overbending, (d) overstraining, or (e) yield strength of the metal?
\r\n20.10 Which of the following are variations of sheet-metal-bending operations (two best answers): (a) coining, (b) flanging, (c) hemming, (d) ironing, (e) notching, (f) shear spinning, (g) trimming, and (h) tube bending?
\r\n20.10 Which of the following are variations of sheet-metal-bending operations (two best answers): (a) coining, (b) flanging, (c) hemming, (d) ironing, (e) notching, (f) shear spinning, (g) trimming, and (h) tube bending?
\r\n20.12 The holding force in drawing is most likely to be (a) greater than, (b) equal to, or (c) less than the maximum drawing force?
\r\n20.13 Which one of the following stamping dies is the most complicated: (a) blanking die, (b) combination die, (c) compound die, (d) edge-bending die, (e) progressive die, or (f) V-bending die?
\r\n20.14 Which one of the following press types is usually associated with the highest production rates in sheet-metal-stamping operations: (a) adjustable bed, (b) open back inclinable, (c) press brake, (d) solid gap, or (e) straight-sided?
\r\n20.15 Which of the following processes are classified as high-energy-rate forming processes (two best answers): (a) electrochemical machining, (b) electromagnetic forming, (c) electron beam cutting, (d) explosive forming, (e) Guerin process, (f) hydroforming, (g) redrawing, and (h) shear spinning
List the factors that affect the hold down pressure in a drawing operation according to the video on sheet-metal stamping dies and processes.
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Name the four forming processes listed in the video clip on sheet-metal stamping dies and processes
According to the video on sheet-metal stamping dies and processes, what are the factors that affect the formability of a metal?
According to the video on sheet-metal bending, what are the principal terms used to describe bending on a press brake?
According to the video on sheet-metal shearing, what is the blade rake angle?
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Distinguish between roll bending and roll forming.
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Identify a major technical problem in tube bending?
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What is the Guerin process?
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What are the relative advantages and disadvantages of mechanical presses versus hydraulic presses in sheet metalworking?
What are the two basic categories of structural frames used in stamping presses?
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Identify the principal components of a stamping die that performs blanking
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What is stretch forming?
What is an embossing operation?
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What are some of the possible defects in drawn sheet-metal parts?
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Distinguish between redrawing and reverse drawing.
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What are some of the simple measures used to assess the feasibility of a proposed cup-drawing operation?
Define drawing in the context of sheet metalworking
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What is springback in sheet-metal bending?
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