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Assignment 1 Eng 221 Metal Forming Second 2023 2024

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16 views3 pages

Assignment 1 Eng 221 Metal Forming Second 2023 2024

Uploaded by

yehia6498
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Assignment 1 METAL FORMING ENG 221

1. Define the followings:


i- Metal forming ii- Isothermal forming iii- Warm forming iv- Strain rate
2. What is flow curve? Discuss the effect of the following parameters on the flow
curve:
i- The specimen temperature ii- Strain rate
3. What is the advantages of warm forming compared to cold? Compared to hot?
4. What is stripper? Explain with sketches the different types of strippers.
5. list the different types of sheet metal dies.
6. What is the difference between compound and progressive dies used in sheet metal
working? Aid your answer with sketches.
7. List the advantages and disadvantages of transfer die used in sheet metal working.
8. What is springback? Why is it of importance in cold forming?
9. Draw sketches showing the difference between fine-edge blanking and fine edge
punching process and then mention the function of impingement ring and counter
holder in this process.
10. List with the aid of a sketch the defects of blanked parts in blanking operations
and explain how you can prevent these defects.
11. In blanking and piercing operations, on what factor does the clearance depends.
12. What are the press and tool requirements for blanking and piercing operations?
13. In a particular blanking and piercing operations, 30 mm blank (or hole) are to be
punched in a steel sheet 2 mm thick. The maximum shear strength of the sheet may
be taken as 370 MPa. Calculate the punch and die size in both blanking and
piercing operations as well as the max shearing force, press capacity and stripping
force (take K = 0.02 kN/mm2).
14. Illustrate the followings:
i- Deep drawing ii- HDD iii- Blank holder
15. Explain with sketches the difference between direct and reverse redrawing then
mention the advantages of reverse redrawing.
16. List with the aid of sketches the defects of deep drawing parts and mention the
reasons of each of them.
17. List the possible reasons for the cup wrinkling and cup fracture during deep
drawing.
18. A circular cup is to be drawn from a steel blank 1mm thick. The outside diameter
of the cup is 61. The cup height is 80 mm. Find out:
i- The blank diameter required to draw the cup,
ii- The number of redraws needed, if the max ratio for drawing is 1.8 and that for
redrawing is 1.2,
19. A circular cup is to be drawn from a steel blank. The outside and inside diameters
of the cup are 81 and 79 mm. The cup height is 110 mm. The flow curve of the
sheet metal is given by: σf = 670 φ0.25 [N/mm2], Find out:
iii- The blank diameter required to draw the cup,
iv-The number of redraws needed, if the max ratio for drawing is 2 and that for
redrawing is 1.3,
v- The drawing force during the first draw when the punch penetrates 0.3 of
the cup heights. (Assume a forming efficiency 0.7).
20. Sketch the die used for wire drawing showing its main parts then mention the
effect of the die angle on friction force and internal shearing force and explain
how you can get the optimum die angle.
21. A steel wire 5.8 mm diameter is drawn to 4.6 mm using a die whose angle is 20º.
The coefficient of friction at the die working surface is 0.1. Calculate the
percentage reduction in the drawing force if a die with an optimum angle was used
22. A steel wire 6.5 mm diameter is drawn to 5.9 mm using a die whose angle is 8º.
The coefficient of friction at the die working surface is 0.1. The wire entering the
die has been subjected to a logarithmic strain = 0.15.
The flow curve is given by: σf = 670 φ0.25 [N/mm2], Find out:
i- The total drawing force.
ii- How much of this force is required to overcome friction force?
iii- How much of this force is required to overcome internal shearing force?
iv- If the ultimate tensile strength of the sheet material is σult. = 420 MPa, is the
operation successful?
v- Calculate the percentage reduction in the drawing force if a die with an
optimum angle was used.
vi- Compare friction force and internal shearing force when the die angle is 8º and
when it is optimum.
23. Illustrate the followings:
i- Wire drawing ii- Bar drawing
24. List with sketches the different types of tube drawing and mention the application
of each method.
25. List with sketches the rolling stand arrangement.
26. Explain with sketches thread and ring rolling as two applications of rolling.
27. In a rolling operation, a steel strip 16 mm thick is reduced to 14 mm by using a
roll 600 mm diameter. The flow stress of the sheet material is 320 MPa, Find out:
i- The angle of bite,
ii- The average roll pressure (Assume frictional shear factor = 0.2).

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