Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 16, Problem 24QLP
Identify the material and process variables that influence the punch force in shearing, and explain how each of them affects this force.
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A spool of wire has a starting diameter of 2.5 mm. It is drawn through a die with an opening that is 2.1 mm at a speed of 0.3 m/s. The worked metal has a strength coefficient of 450 MPa and a strain-hardening coefficient of 0.26. Assume the drawing is performed at room temperature and that the frictional and redundant work together constitute 35% of the ideal work of deformation.
Calculate the power required to carry out the operation
The figure below shows a symmetric plane-strain upsetting process. The process may also be thought of as a form of side extrusion. Observations show that the deformation is confined to two shear planes, each one being analogous to that seen in plane-strain cutting. You may assume that there is no friction between the work material and the tool/die walls; the uniaxial yield strength of the material is σy and is independent of strain rate and temperature, and the material behaves as a rigid plastic solid.
a) Calculate the pressure (p) required for the upsetting process in terms of σy.
b) If friction existed at the die walls and the frictional work (energy) dissipation was 30% of the energy required for shape change alone (part (a) above), then what would be the pressure (p)?
A plate that is 250 mm wide and
25 mm thick is to be reduced in a
single pass in a two-high rolling
mill to a thickness of 20 mm. The
roll has a radius = 500 mm, and its
speed = 30 m/min. The work
material has a strength coefficient
= 240 MPa and a strain hardening
exponent = 0.2. Determine (a)roll
force, (b) roll torque, and (c)
power required to accomplish this
.operation
1365 N & 529865 N-m & 452 W O
500250 N & 12005 N-m & 2456 W O
71254632 N & 135674 N-m & 12053 W O
1851829 N & 46296 N-m & 92,591 W O
Chapter 16 Solutions
Manufacturing Engineering & Technology
Ch. 16 - How does sheet-metal forming differ from rolling,...Ch. 16 - What causes burrs? How can they be reduced or...Ch. 16 - Prob. 3RQCh. 16 - Describe the difference between compound,...Ch. 16 - Describe the characteristics of sheet metals that...Ch. 16 - Describe the features of forming-limit diagrams...Ch. 16 - List the properties of materials that influence...Ch. 16 - Give one specific application for each of the...Ch. 16 - Why do tubes buckle when bent? What is the effect...Ch. 16 - Define normal anisotropy, and explain why it is...
Ch. 16 - Describe earing and why it occurs.Ch. 16 - What are the advantages of rubber forming? Which...Ch. 16 - Explain the difference between deep drawing and...Ch. 16 - How is roll forming fundamentally different from...Ch. 16 - What is nesting? What is its significance?Ch. 16 - Describe the differences between compound,...Ch. 16 - What is microforming?Ch. 16 - Explain the advantages of superplastic forming.Ch. 16 - What is hot stamping? For what materials is it...Ch. 16 - What is springback? What is negative springback?Ch. 16 - Explain the differences that you have observed...Ch. 16 - Take any three topics from Chapter 2, and, with...Ch. 16 - Do the same as for Problem 16.22, but for Chapter...Ch. 16 - Identify the material and process variables that...Ch. 16 - Explain why springback in bending depends on yield...Ch. 16 - Explain why cupping tests may not predict well the...Ch. 16 - Identify the factors that influence the...Ch. 16 - Why are the beads in Fig. 16.36b placed in those...Ch. 16 - A general rule for dimensional relationships for...Ch. 16 - Section 16.2 stated that the punch stripping force...Ch. 16 - Is it possible to have ironing take place in an...Ch. 16 - Note the roughness of the periphery of the flanged...Ch. 16 - What recommendations would you make in order to...Ch. 16 - It has been stated that the quality of the sheared...Ch. 16 - Give several specific examples from this chapter...Ch. 16 - As you can see, some of the operations described...Ch. 16 - Through changes in clamping or die design, it is...Ch. 16 - How would you produce the part shown in Fig....Ch. 16 - It has been stated that the thicker the sheet...Ch. 16 - Prob. 41QTPCh. 16 - Calculate the value of R in Problem 16.41. Will...Ch. 16 - Estimate the limiting drawing ratio for the...Ch. 16 - Using Eq. (16.15) and the K value for TNT, plot...Ch. 16 - Section 16.5 states that the k values in bend...Ch. 16 - For explosive forming, calculate the peak pressure...Ch. 16 - Measure the respective areas of the solid outlines...Ch. 16 - Plot Eq. (16.6) in terms of the elastic modulus,...Ch. 16 - What is the minimum bend radius for a 1.0-mm-thick...Ch. 16 - Survey the technical literature and explain the...Ch. 16 - Using the data in Table 16.3 and referring to Eq....Ch. 16 - What is the force required to punch a square hole...Ch. 16 - In Case Study 16.2, it was stated that the reason...Ch. 16 - A cup is being drawn from a sheet metal that has a...Ch. 16 - Prob. 55QTPCh. 16 - Figure P16.57 shows a parabolic profile that will...Ch. 16 - Prob. 59SDPCh. 16 - Consider several shapes to be blanked from a large...Ch. 16 - Prob. 61SDPCh. 16 - Many axisymmetric missile bodies are made by...Ch. 16 - Metal cans are either two-piece (in which the...Ch. 16 - The design shown in Fig. P16.65 is proposed for a...Ch. 16 - Suggest consumer-product designs that could...Ch. 16 - How would you produce the part shown in Fig. 16.44...Ch. 16 - Using a ball-peen hammer, strike the surface of...Ch. 16 - Inspect a common paper punch and observe the shape...Ch. 16 - Obtain an aluminum beverage can and slit it in...Ch. 16 - Prob. 71SDPCh. 16 - Prob. 73SDPCh. 16 - On the basis of experiments, it has been suggested...Ch. 16 - Design a box that will contain a 4-in. 6-in. ...Ch. 16 - Repeat Problem 16.77, but design the box from a...
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Need a deep-dive on the concept behind this application? Look no further. Learn more about this topic, mechanical-engineering and related others by exploring similar questions and additional content below.Similar questions
- Compare hot and cold rolling products in terms of surface quality, mechanical properties, force required for rolling.arrow_forwardEstimate the power for annealed low carbon steel strip 200 mm wide and 10 mm thick, rolled to a thickness of 6 mm. The roll radius is 200 mm, and the roll rotates at 200 rev/min; use coefficient of friction at the die-work interface (p)=0.1. A low carbon steel such as AISI 1020 has K (strength coefficient) = 530 MPa and n ( strain hardening exponent) =0.26a)1059 kWb)950 kWc)1183 kWd)875 kWarrow_forwardExplain why and how various factors influence springback in bending of sheet metals.arrow_forward
- 2. A 300 mm wide, 40 mm thick plate is reduced to 30 mm thickness in one pass by hot rolling. Roll diameter is 200 mm and entrance speed is 16 m/min. Material constants C and m at the process temperature are given as 50 MPa and 0.05 respectively. Determine: a. The minimum friction coefficient required to make this operation possible, b. Assuming that the minimum level of friction is maintained, calculate the exit velocity of the plate by considering there is no widening, c. Calculate the force and power requirement to apply the pass.arrow_forward(c) A flat rolling operation is being carried out where the roll radius is 200 mm and the roll rotates at 100 rpm. The workpiece material is annealed low carbon steel with 200 mm wide and 10 mm thickness. The strength coefficient and the strain hardening of the carbon steel are 530 MPa and 0.26, respectively. The coefficient of friction is 0.2. (i) Caicurae tne roll force and torque if the workpiece is rolled to a thickness of 4 mm. (ii) Calculate the maximum possible draft and evaluate how friction effect the thickness of the rolled workpiece.arrow_forwardIn a blanking operation to produce steel washer, the maximum punch load used is 3 x 105 N. The plate thickness is 5 mm and percentage penetration is 25. What is the work done during this shearing operation?arrow_forward
- Derive the expression for roll separating force and power in rolling.arrow_forwardWould you kindly answer this question A rolling operation on a 250 mm wide, 8 mm thick, 1112 cold rolled steel takes place using hardened steel rolls with a surface finish of 0.03 μm. The rolls have a diameter of 350 mm and rotates at 115 rpm. The final thickness of the plate is 6 mm and the entry speed of the plate is 1.8 m/s. Calculate: 3.1 The minimum coefficient of friction required, that will make the rolling operation possible. 3.2 The required roll force. 3.3 The position of the neutral point, ?? 3.4 Indicate, using a sketch, the neutral point showing all relevant notation and dimensions.arrow_forwardA 300 mm thick slab is being cold rolled using roll of 600 mm diameter. If the coefficient of friction is 0.08, the maximum possible reduction is,arrow_forward
- A low-carbon steel plate is 300 mm wide and 25 mm thick. It is reduced in one pass in a two-high rolling mill to a thickness of 20 mm. Roll radius = 300 mm, and roll speed = 30 m/min. Strength coefficient = 500 MPa, and strain hardening exponent = 0.25. Determine the (a) roll force, (b) roll torque, and (c) power required to perform this operation.arrow_forwardA cylindrical part is warm upset forged in an open die. The initial diameter is 50 mm and the initial height is 40 mm. The height after forging is 30 mm. The coefficient of friction at the die-work interface is 0.25. The yield strength of the work material is 285 MPa, and its flow curve is defined by a strength coefficient of 600 MPa and a strain-hardening exponent of 0.12. Calculate the strain at yield point.arrow_forwardAn open die forging operation is performed to produce a steel cylinder with a diameter of 9.7mm and a height of 1.7mm. The strength coefficient for this steel is 500MPA, and the strain hardening exponent is 0.25. Coefficient of friction at the die-work interface is 0.12. The initial stock of raw material has a diameter of 5mm. (a) What height/length of stock is needed to provide sufficient volume of material for this forging operation? (b) Compute the maximum force that the punch must apply to form the head in this open- die operation.arrow_forward
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