Industrial Engineering Program Assignment 3

IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

Summary

Shearing Process

Clearance: 𝒄 = 𝑨𝒄 𝒕

Blanking punch diameter = Db - 2c

Blanking die diameter = Db

Shearing Force: 𝑭 = 𝑺 ∗ 𝒕 ∗ 𝑳

or

Shearing Force: 𝑭 = 𝟎. 𝟕 ( 𝑻𝑺) ∗ 𝒕 ∗ 𝑳

1
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

Bending Process

𝜶
Bend Allowance: 𝑨𝒃 = 𝟐 𝝅 (𝑹 + 𝑲𝒃𝒂 𝒕)
𝟑𝟔𝟎

𝑲𝒃𝒂 = 𝟎. 𝟑𝟑, If R (bend radius) < 2𝒕

𝑲𝒃𝒂 = 𝟎. 𝟓𝟎, If R (bend radius) ≥ 2𝒕

𝑲𝒃𝒇 ∗(𝑻𝑺)∗𝒘∗𝒕𝟐
Bending Force: 𝑭 =
𝑫

𝑲𝒃𝒇 = 𝟏. 𝟑𝟑, for v-bending process.

𝑲𝒃𝒇 = 𝟎. 𝟑𝟑, for edge bending process.

2
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

Deep Drawing

Clearance: 𝒄 = 𝟏. 𝟏 𝒕

𝑫𝒃
Drawing ratio: 𝑫𝑹 =
𝑫𝒑

𝑫𝒃 −𝑫𝒑
Reduction ratio: 𝒓 =
𝑫𝒃

𝒕
Thickness-to-diameter ratio=
𝑫𝒃

𝑫𝒃
Drawing Force: 𝑭 = 𝝅 ∗ 𝑫𝒑 ∗ 𝒕 ∗ (𝑻𝑺) ∗ ( − 𝟎. 𝟕)
𝑫𝒑

𝟐
Blank holder Force: 𝑭𝒉 = 𝟎. 𝟎𝟏𝟓 ∗ 𝒀 ∗ 𝝅 ∗ {𝑫𝒃 𝟐 − (𝑫𝒑 + 𝟐. 𝟐𝒕 + 𝟐𝑹𝒅 ) }

3
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

1. What is Constitutive Modelling?

2. How does increasing temperature affect the parameters in the flow curve
equation?

3. Describe the effect of strain rate in metal forming.

4. What is the effect of increased workpiece temperature on the strain rate

sensitivity exponent?

5. What is the difference between bulk deformation and sheet metal forming?

4
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

6. Identify the three basic types of sheet metal forming operations.

7. In conventional sheet metal forming operations, (a) what is the name of the
tooling and (b) what is the name of the machine tool used in the operations?

8. Why is the term pressworking often used for sheet metal processes?

9. The three basic sheet metal forming operations are bending, drawing, and
shearing. What makes shearing different from the other two operations?

10.What are some of the advantages of cold working relative to warm and hot
working?

5
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

11.What is isothermal forming?

12.Why is friction generally undesirable in metal forming operations?

13.What is sticking friction in metal forming?

14.In blanking of a circular sheet-metal part, is the clearance applied to the

punch diameter or the die diameter?

15.What is the difference between a cutoff operation and a parting operation?

6
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

16.What is springback in sheet-metal bending?

17.Define drawing in the context of sheet metal forming.

18.What are some of the simple measures used to assess the feasibility of a
proposed cup-drawing operation?

19.What are some possible defects in drawn sheet-metal parts?

20.What is the difference between redrawing and reverse drawing?

7
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

21. The foreman in the drawing section of the shop shows you several samples
of parts that have been deep drawn in the shop. The samples have various
defects. One has ears, another has wrinkles, and a third has torn sections at
its base. What are the causes of each defect and what remedies would you
propose?

8
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

22. Power shears are used to cut a sheet of soft cold-rolled steel (Ac =
0.060) that is 2.4 mm thick and 1.25 m wide. The steel has a yield
strength = 175 MPa and a tensile strength = 300 MPa. Determine (a)
the clearance that should be used to produce an optimum cut and (b)
the shearing force in the operation.

9
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

23. A blanking operation is performed on 1/8-in-thick cold-rolled steel (Ac =

0.075). The part is circular with diameter = 2.500 in. The shear strength of
the steel = 40,000 lb/in2 and the tensile strength is 55,000 lb/in2. Determine
(a) the appropriate punch and die sizes for the operation and (b) the
blanking force required.

10
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

24. A compound die is used to blank and punch a large washer out of 6061ST
aluminum alloy sheet (Ac = 0.060) stock 3.2 mm thick. The aluminum has
a tensile strength = 350 MPa. 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. (c)
determine the force required to perform the blanking and punching
operation occurred simultaneously, and (d) if the punches are staggered so
that punching occurs first, then blanking.

11
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

25. A blanking die must be designed to blank the part depicted below. The
material is 4 mm-thick stainless steel (Ac = 0.075). Determine (a) the
dimensions of the blanking punch and the die opening and (b) the shearing
force required, given that the stainless steel has a yield strength = 275 MPa,
shear strength = 450 MPa, and tensile strength = 650 MPa.

12
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

26. A bending operation is to be performed on 5.00 mm thick cold-rolled steel

to produce the part which is depicted in the below figure. Determine (a)
the blank size required and (b) the bending force 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.

13
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

27. A bending operation is performed on a 4.0 mm-thick cold-rolled steel

sheet that is 25 mm wide and 100 mm long. The sheet is bent along the
25 mm direction, so that the bend axis is 25 mm long. The resulting
sheet metal part has an acute angle of 30 and a bend radius of 6 mm.
Determine (a) the bend allowance, and (b) the bending force 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.

14
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

28. An angle bracket is bent in a V bending operation on a press brake from a

flat blank that is 4.0 inch long by 1.5 inch wide by 5/32 inch thick. The 90
bend is made in the middle of the 4 inch length, so that the bend axis is 1.5
inch long. Determine (a) the bend allowance, and (b) the bending force
required if the die opening dimension = 1.0 in. The material has a tensile
strength = 50,000 lb/in2.

15
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

29. A cylindrical cup is produced in a deep drawing operation. Cup height =

75 mm, and 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?

16
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

30. A deep drawing operation is performed to produce a cylindrical cup in

which the inside diameter = 4.25 in and height = 2.65 in. Stock thickness
= 3/16 in, and blank diameter = 7.7 in. Punch and die radii = 5/32 in. The
metal has a tensile strength = 65,000 lb/in2, a yield strength = 32,000 lb/in2,
and a shear strength of 40,000 lb/in2. Determine (a) drawing ratio, (b)
reduction, (c) drawing force, and (d) blank-holder force.

17
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

31. A cup-drawing operation is performed in which the cup’s inside diameter = 80

mm and its height = 50 mm. Stock thickness = 3.0 mm, and blank diameter = 150
mm. Punch and die radii = 4 mm. Tensile strength = 400 MPa and yield strength
= 180 MPa for this sheet metal. Determine (a) drawing ratio, (b) reduction, (c)
drawing force, and (d) blank-holder force.

18
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

32. A deep drawing operation is performed on a sheet-metal blank that is 1/8 in thick. The
height of the cup = 3.8 in and its diameter = 5.0 in (both inside dimensions). (a)
Assuming the punch radius = 0, compute the starting diameter of the blank to complete
the operation with no material left in the flange. (b) Is the operation feasible (ignoring
the fact that the punch radius is too small)?

19
 Industrial Engineering Program Assignment 3
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

33. A drawing operation is performed on 3.2 mm stock. The part is a cylindrical cup
with inside height = 40 mm and inside diameter = 60 mm. Assume the corner
radius on the punch is zero. (a) Find the required starting blank size Db. (b) Is the
drawing operation feasible?

20