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Manufacturing Process > Week 3 > Flashcards

Week 3 Flashcards

1
Q

What is the definition of sheet metalworking?;

A

Cutting and forming operations performed on relatively thin sheets of metal.

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2
Q

What is the typical thickness range of sheet metal?;

A

0.4 mm (1/64 in) to 6 mm (1/4 in).

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3
Q

At what thickness does sheet metal become plate stock?;

A

Greater than 6 mm.

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4
Q

What is the usual temperature condition for operations in sheet metalworking?;

A

Cold working.

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5
Q

What are the advantages of sheet metal parts?;

A

good dimensional accuracy, High strength

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6
Q

Why are sheet metal parts suitable for large quantities?;

A

Economical mass production operations are available.

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7
Q

What is the function of ‘punch-and-die’ in sheet metalworking?;

A

Tooling to perform cutting bending

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8
Q

What is a ‘stamping press’ used for in sheet metalworking?;

A

It is a machine tool that performs most sheet metal operations.

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9
Q

What are ‘stampings’ in the context of sheet metalworking?;

A

They are sheet metal products.

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10
Q

What is the process of shearing used for in sheet metalworking?;

A

To separate large sheets cut part perimeters

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11
Q

What is the purpose of bending in sheet metalworking?;

A

To strain the sheet around a straight axis.

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12
Q

What is the process of drawing used for in sheet metalworking?;

A

Forming the sheet into convex or concave shapes.

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13
Q

What is shearing in sheet metalworking?;

A

It is the process of cutting sheet metal between two sharp cutting edges.

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14
Q

What causes plastic deformation in the shearing process?;

A

The punch begins to push into the work.

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15
Q

What are the three principal operations in pressworking that cut sheet metal?;

A

Shearing Blanking

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16
Q

What is shearing in sheet metal cutting?;

A

It is a cutting operation along a straight line between two cutting edges.

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17
Q

What is the typical purpose of shearing in sheet metal cutting?;

A

To cut large sheets into smaller sections for subsequent operations.

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18
Q

What is blanking in sheet metalworking?; Sheet metal cutting to separate a piece from surrounding stock

A

with the cut piece being the desired part

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19
Q

What is the cut piece called in blanking?;

A

A blank.

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20
Q

What is punching in sheet metalworking?;

A

Sheet metal cutting similar to blanking where the cut piece is scrap

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21
Q

What is the cut piece called in punching?;

A

A slug.

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22
Q

What is clearance in sheet metal cutting?;

A

The distance between the punch and die.

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23
Q

What are the typical values for clearance in sheet metal cutting?;

A

Typical values range between 4% and 8% of stock thickness.

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24
Q

What issues can arise if the clearance in sheet metal cutting is too small?;

A

Fracture lines pass each other causing double burnishing and larger force.

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25
Q

What issues can arise if the clearance in sheet metal cutting is too large?;

A

Metal is pinched between cutting edges and excessive burr results.

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26
Q

How can recommended clearance in sheet metal cutting be calculated?;

A

By using the formula: c = at
c = clearance
a= allowance
t = stock thickness

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27
Q

What does die size determine in blanking?;

A

Blank size (D b).

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28
Q

What does punch size determine in blanking?;

A

Hole size (D h).

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29
Q

How is the blanking punch diameter calculated for a round blank?;

A

D b - 2c.

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30
Q

How is the blanking die diameter calculated for a round blank?.

A

D b

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31
Q

How is the hole punch diameter calculated for a round hole?; .

A

D h

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32
Q

How is the hole die diameter calculated for a round hole?;

A

D h + 2c.

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33
Q

What is the formula for calculating punch diameter?;

A

Punch diameter = D b - 2c

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34
Q

What is the purpose of angular clearance in manufacturing processes?;

A

To allow slug or blank to drop through the die.

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35
Q

What are the typical values for angular clearance on each side?;

A

0.25 degrees to 1.5 degrees.

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36
Q

What is the formula for calculating cutting force?;

A

F = S * t * L

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37
Q

Why are cutting forces important in determining press size?;

A

They help determine the required tonnage for the press.

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38
Q

What does ‘S’ represent in the cutting force formula?;

A

Shear strength of the metal.

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39
Q

How is ‘t’ defined in the cutting force formula?;

A

Stock thickness.

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40
Q

What does ‘L’ stand for in the cutting force formula?;

A

Length of the cut edge.

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41
Q

What is the formula for force (F) in the given solution?;

A

F = StL

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42
Q

What is bending in sheet metalworking?;

A

It is straining sheet metal around a straight axis to take a permanent bend.

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43
Q

What happens to the metal on the inside of the neutral plane during bending?;

A

It is compressed.

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44
Q

What happens to the metal on the outside of the neutral plane during bending?;

A

It is stretched.

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45
Q

What is V-bending in sheet metalworking?;

A

It is performed with a V-shaped die.

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46
Q

How is edge bending performed in sheet metalworking?;

A

It is performed with a wiping die.

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47
Q

What type of production is V-bending suitable for?; .

A

Low production

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48
Q

Where is V-bending typically performed?; .

A

On a press brake

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49
Q

What are the characteristics of V-dies used in V-bending?;

A

Simple and inexpensive.

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50
Q

What is the purpose of edge bending?;

A

To create a bend in the edge of a workpiece.

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51
Q

Why is a pressure pad required in edge bending?;

A

To ensure proper contact and support during the bending process.

52
Q

What is a characteristic of dies used in edge bending?;

A

They are more complicated and costly.

53
Q

What happens to the metal during bending if the bend radius is small relative to stock thickness?;

A

The metal tends to stretch.

54
Q

Why is it important to estimate the amount of stretching during bending?;

A

To ensure that the final part length matches the specified dimension.

55
Q

What is the formula for bend allowance (BA)?;

A

BA = 2π(α/360)(R + Kbat).

BA = bend allowance
t = thickness
A = bend angle
R=bend radius
kba = factor to estimate bending

56
Q

When is the value of Kba 0.33 in the bend allowance formula?;

A

When R < 2t.

57
Q

When is the value of Kba 0.50 in the bend allowance formula?;

A

When R ≥ 2t.

58
Q

What is the formula for BA (Blanking Allowance)?;

A

BA = 2π(α/360)(R + Kbat).

59
Q

What is springback in bending?;

A

It is the increase in the included angle of the bent part relative to the included angle of the forming tool after the tool is removed.

60
Q

What causes springback in bending?;

A

When bending pressure is removed elastic energy remains in the bent part

61
Q

What is springback in bending?;

A

It shows itself as a decrease in bend angle and an increase in bend radius.

62
Q

What happens to the work during bending?;

A

It is forced to take the radius and included angle of the bending tool.

63
Q

What occurs after the punch is removed in bending?;

A

The work springs back to radius and angle.8888888888

64
Q

How is the maximum bending force estimated?;

A

F = 1.33 * TS * w * t for V-bending
F = 0.33 * TS * w * t for edge bending.

65
Q

How is the sheet metal blank positioned to create the desired shape in drawing?;

A

Over the die cavity then the punch pushes the metal into the opening.

66
Q

What are some products that are manufactured using the drawing process in sheet metal forming?;

A

Beverage cans & ammunition shells

67
Q

What does DR stand for in the context of drawing operations?;

A

Drawing Ratio.

68
Q

How is the Drawing Ratio (DR) calculated?;

A

By dividing the punch diameter (Dp) by the blank diameter (Db).

69
Q

What does a Drawing Ratio (DR) value of 2 indicate?;

A

It indicates severity of a given drawing operation.

70
Q

For which shape is the Drawing Ratio (DR) most easily defined?;

A

Cylindrical shape.

71
Q

What is the condition for the value of r in the context of cylindrical shape reduction?;

A

The value of r should be less than 0.50.

72
Q

What does the thickness-to-diameter ratio (t/Db) represent?;

A

The thickness of the starting blank divided by the blank diameter.

73
Q

What is the desirable range for the thickness-to-diameter ratio (t/Db)?;

A

Greater than 1%.

74
Q

What happens as the thickness-to-diameter ratio (t/Db) decreases?;

A

There is an increased tendency for wrinkling.

75
Q

What is the formula for drawing force in sheet metalworking?;

A

F = πDpt(TS)(Db/Dp - 0.7)

76
Q

What does TS represent in the drawing force formula?;

A

Tensile strength.

77
Q

What is the formula for holding force in sheet metalworking?;

A

Fh = 0.015Yπ(Db^2 - (Dp + 2.2t + 2Rd)^2)

78
Q

What does Y represent in the holding force formula?;

A

Yielding point.

79
Q

What is the formula for calculating the drawing ratio?;

A

Drawing ratio = Blank diameter / Inside diameter.

80
Q

How do you calculate the reduction in a deep drawing operation?;

A

Reduction = (Blank diameter - Inside diameter) / Blank diameter.

81
Q

What is the formula for the thickness-to-diameter ratio in deep drawing?;

A

Thickness-to-diameter ratio = Sheet metal thickness / Inside diameter.

82
Q

Based on the given parameters does the deep drawing operation seem feasible?;

A

Feasibility depends on the calculated drawing ratio

83
Q

What does DR represent in the given solution?;

A

DR represents the drawing ratio and is calculated as D b / D p.

84
Q

How is the reduction in area (r) calculated?;

A

The reduction in area (r) is calculated as (D b - D p) / D b.

85
Q

What does the value t / D b represent in the given solution?;

A

The value t / D b represents the thickness-to-diameter ratio.

86
Q

Why is the feasibility of the process considered not possible in the given solution?;

A

The drawing ratio (DR) is too large (greater than 2.0)
the reduction in area (r) is too large (greater than 50%)

87
Q

What is the purpose of blank size determination in sheet metalworking?;

A

To ensure the final dimensions of the drawn shape are correct.

88
Q

How is the starting blank diameter (D b) determined?;

A

By setting the starting sheet metal blank volume equal to the final product volume.

89
Q

What assumption is made to facilitate the calculation of blank size?;

A

Negligible thinning of the part wall.

90
Q

What are some shapes produced by deep drawing other than cylindrical cups?;

A

Square or rectangular boxes stepped cups

91
Q

What unique technical problems do different shapes present in deep drawing?;

A

Each shape presents its own unique technical problems.

92
Q

What are some sheet metal forming operations performed on conventional presses?;

A

Operations performed with metal tooling.

93
Q

What type of tooling is used for sheet metal forming operations on conventional presses?;

A

Metal tooling.

94
Q

What are some sheet metal forming operations performed with flexible rubber tooling?;

A

Operations performed with flexible rubber tooling.

95
Q

What does ironing achieve in the manufacturing process?;

A

It makes the wall thickness of a cylindrical cup more uniform.

96
Q

What is the purpose of ironing in the production of a drawn cup?;

A

To achieve a more uniform wall thickness.

97
Q

What is embossing used to create in a sheet?;

A

Indentations such as raised lettering or strengthening ribs.

98
Q

What is the purpose of embossing in manufacturing processes?;

A

To create indentations in a sheet for various purposes.

99
Q

What are most pressworking operations performed with?;

A

Conventional punch-and-die tooling.

100
Q

What term is sometimes used for high production dies?;

A

Stamping die.

101
Q

What is the configuration of a gap frame stamping press?;

A

It is in the shape of the letter C and often referred to as a C-frame.

102
Q

How is a straight-sided frame stamping press constructed?;

A

It has a box-like construction for higher tonnage.

103
Q

What type of system do hydraulic presses use to drive the ram?;

A

They use a large piston and cylinder.

104
Q

What type of operations are hydraulic presses suited to?;

A

They are suited to deep drawing.

105
Q

How does a mechanical press convert the rotation of the motor?;

A

It converts it to the linear motion of the ram.

106
Q

What type of operations are mechanical presses suited to?;

A

They are suited to blanking and punching.

107
Q

What is stretch forming in sheet metal operations?;

A

A process not performed on presses.

108
Q

What is roll bending and forming in sheet metal operations?;

A

A process not performed on presses.

109
Q

What is spinning in sheet metal operations?;

A

A process not performed on presses.

110
Q

What is stretch forming in sheet metalworking?;

A

It involves stretching and bending sheet metal simultaneously to achieve a shape change.

111
Q

What happens at the start of the stretch forming process?;

A

The form die is pressed into the work with force ausing the sheet metal to be stretched and bent over the form.

112
Q

What is the force responsible for stretching the sheet metal in stretch forming?;

A

The stretching force (F).

113
Q

What is the formula for the stretching force in stretch forming?;

A

F = f L t Yf

114
Q

How is the die force (Fdie) determined in stretch forming?;

A

By balancing vertical force components.

115
Q

What is roll bending used for?;

A

Forming large metal sheets and plates into curved sections.

116
Q

How are curved sections formed using roll bending?;

A

Using rolls.

117
Q

What is roll forming?;

A

A continuous bending process using opposing rolls to produce long sections of formed shapes from coil or strip stock.

118
Q

What is spinning in metal forming?;

A

A process in which an axially symmetric part is gradually shaped over a rotating mandrel using a rounded tool or roller.

119
Q

What are the three types of spinning?;

A
  1. Shear spinning
120
Q

What is High-Energy-Rate Forming (HERF)?;

A

A process to form metals using large amounts of energy over a very short time.

121
Q

What are the types of HERF processes?;

A

Explosive forming
Electrohydraulic forming

122
Q

What is Explosive Forming?;

A

It is the use of an explosive charge to form sheet (or plate) metal into a die cavity.

123
Q

How is the energy for forming transmitted in Explosive Forming?;

A

The explosive charge causes a shock wave whose energy is transmitted to force the part into the cavity.

124
Q

What are the typical applications of Explosive Forming?;

A

Large parts typical of the aerospace industry.

125
Q

What is Electromagnetic Forming in sheet metalworking?;

A

It is the process where sheet metal is deformed by the mechanical force of an electromagnetic field induced in the workpart by an energized coil.

126
Q

What is the most widely used HERF process at present?;

A

Electromagnetic Forming.

127
Q

What are some applications of Electromagnetic Forming?;

A

Tubular parts.

Manufacturing Process (11 decks)

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