MA2004 Manufacturing Processes

Tutorial 3 Sheet Metalworking (Semester 1 AY2015-2016)

For weeks 5 and 6 (starting on 7 and 14 Sep 2015)

Part A: Basic review questions (these questions will not be discussed in class)
A.1. Which one of the following is the correct definition of ultimate tensile strength, as
derived from the results of a tensile test on a metal specimen: (a) the stress
encountered when the stress-strain curve transforms from elastic to plastic behavior,
(b) the maximum load divided by the final area of the specimen, (c) the maximum load
divided by the original area of the specimen, or (d) the stress observed when the
specimen finally fails?

A.2. In blanking of a circular sheet-metal part, is the clearance applied to the punch
diameter or the die diameter? Why?

A.3. A power shear 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?
[Ans: c = 0.285 mm]
A.4. An L-shaped part is to be bent in an edge-bending operation on a press brake from a
flat blank of size 10 cm by 3.8 cm that is 0.39 cm thick. The bend of 90 is to be made
in the middle of the 10 cm length. The material has a tensile strength = 480 MPa and
the bend radius = 0.47 cm. The operation is performed using a wiping die with die
opening dimension = 1.875 cm. Calculate the required bending force.
[Ans: F = 4.88 kN]
A.5. What are some of the possible defects in drawn sheet-metal parts?

A.6. A cup is to be drawn in a deep drawing operation. The height of the cup is 75 mm and
its inside diameter = 100 mm. The sheet-metal thickness = 2 mm. If the blank diameter
= 225 mm, determine (a) drawing ratio, (b) reduction, and (c) thickness-to-diameter
ratio. (d) Does the operation seem feasible?
[Ans: (a) 2.25, (b) 55.6%, (c) 0.89%, (d) No]
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Part B: Discussion questions (these questions will be discussed in class)

B.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 (a) the punch and die sizes for the
blanking operation, (b) the punch and die sizes for the punching operation, (c) the
total force required if the blanking and punching operations are done simultaneously
and the tensile strength of the aluminum = 310 MPa.
[Ans: (a) Punch = 49.58 mm, Die = 50.00 mm (b) Punch = 15.00 mm, Die =
15.42 mm, (c) F = 155,092 N]
B.2. A blanking die is to be designed to blank the part outline shown in Figure 1. The
material is 3 mm thick stainless steel (half hard). Determine the dimensions of the
blanking punch and the die opening. Present your results on drawings that show the
dimensions of the cross-section of the punch and die.
[Ans: 85/50/25/25/84.55/49.55/24.55/25 mm]

Figure 1. Blanked part for problem B.2. All dimensions in mm.

B.3. A bending operation is to be performed on 5.00 mm thick cold-rolled steel. The part
drawing is given in Figure 2. Determine (a) the blank size required, (b) the bending
force required if the bend is to be performed in a V-die with a die opening dimension
of 40 mm. The material has a tensile strength of 600 MPa and a shear strength of 430
MPa.
[Ans: (a) w = 35 mm, L = 138.34 mm, (b) F = 17,456 N]

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11.35

Figure 2. Part in bending operation for problem B.3. All dimensions in mm.

B.4. A cup is to be drawn in a deep drawing operation. The height of the cup is 75 mm and
its inside diameter = 100 mm. The sheet-metal thickness = 2 mm. If the blank diameter
= 175 mm, determine (a) drawing ratio, (b) reduction, and (c) thickness-to-diameter
ratio. (d) Does the operation seem feasible?
[Ans: (a) 1.75, (b) 42.9%, (c) 1.14%, (d) No]

B.5. A deep drawing operation is performed in which the inside of the cylindrical cup has a
diameter of 8.0 cm and a height = 5.0 cm. The stock thickness = 0.3 cm, and the
starting blank diameter = 15.0 cm. Punch and die radii = 0.4 cm. The metal has a
tensile strength = 400 MPa, a yield strength = 180 MPa, and a shear strength of 210
MPa. Determine (a) drawing ratio, (b) reduction, (c) drawing force, and (d) blankholder
force.
[Ans: (a) 1.875, (b) 46.7%, (c) F = 354.37 kN, (d) Fh = 28.74 kN]

Remark: No formulae will be given during the exam except these 3:

Bending Force: =

() 2

Drawing Force: = () 0.7

Blank Holder Force: =

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0.015 2
2
+ 2.2 + 2
4