5.1 Calculate the final bend radius for a 3 mm thick 6061 T6 aluminum plate that is formed using a forming punch with an 8 mm radius, as shown in Figure 3. R 8 Figure 3: Bend profile that is formed using a V-block die and a punch with a 8 mm radius 5.2 Explain why there would be a difference between the initial and final bend radius during the bending process and how this occurrence depends upon material properties, sheet thickness and the bend radius.

I think the answer is 0Mpa , Looking for Explanation.

find the die shape factor in an extrusion process, if the diameter of the extruded cross-section is =15 cm and the diameter of the circle of the same area as the extruded shape is = 10 cm

Calculate (1) die pressure distribution and (2) forging force for plane strain forging (open die forging). Assume yield strength of the material is Y, and yielding criterion is von Mises. ho 2Lo h Forged to 2L xdx L 'x+value Note: Assume Zo Constant Plane strain Die pressure distribution h L L Die pressure distribution h MATERIAL L dx -(-1) Friction Hill Y L When 0; =Y P=Y' = Calculate forging force X L dF elemental volume Average pressure

A hot/cold rolling setup is shown right. The operation first hot rolls a 3/8” thick plate, 12” wide (w), of6061 Aluminum, to an intermediate thickness, then finally through cold rolling, down to 1/4” thick plate.The friction factor μ is assumed to be constant at 0.15 for the hot roll, 0.12 for the cold rolling stage. Thefirst set of rolls operate at 50 RPM. Also ignore any width increase during rolling. CW=13% or .13   What is the plate thickness (mm) prior to the last rolls, t1, if the last set of rollers perform cold work reduction listed below at .13 or 13% Note that 9.52 mm is equal to 3/8 of an inch.

A compound die will be used to blank and punch a large rectangle (90x150mm blank dimensions) out of 6061ST aluminum alloy sheet stock 3.5 mm thick. The diameter of inside hole is 25 mm. The aluminum sheet metal has a tensile strength 310 MPa. Determine the minimum tonnage press (force) to perform the blanking and punching operation (1) assume that blanking and punching occur simultaneously and (2) assume that punching occurs first, then blanking, Take: Ac-0.06

A small connecting rod is forged from AISI 1015 steel at 1200oC. Calculate the forging force in a mechanical press at a speed of 200 mm / s when the die comes into contact with the part. The volume of the connecting rod is estimated to be 28680 mm3, and 20% of the starting material is expected to burn off as flash (flash). In the final form the projected area is 3500 mm2 without flash. The width of the flash is 7.6mm around 300mm in circumference.

Using average pressure formulas and ignoring barrelling, plot the force (vertical axis) versus reduction-in-height (horizontal axis is *100) curve in open-die forging of a cylindrical, annealed copper specimen whose height is 1 in and diameter is 1 in, from reduction-in-height of 0% to 75%, when the friction between the flat dies and the specimen ho-h ho is a) μ = 0 b) μ c) μ = 0.1 0.2

Assume you are bending a 3/16” thick rolled plate of Al 6061-T6 at a 90-degree angle. The initial bend radius (after the part is bent in the press brake) is 0.35”. Look up material properties on the Internet a) What is the final bend radius after the part has “relaxed”?b) Is it within the 2-4% rule of thumb?Show your work, and write down any values you choose to reference/use.