- As A Manufacturing Engineer In A Metal Forming Industry You Are Requested To Manufacture A Cup As Shown In Figure 1 Th 1 (101.63 KiB) Viewed 41 times
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As a manufacturing engineer in a metal forming industry, you are requested to manufacture a cup as shown in Figure 1. The available material in the market is naval brass (annealed), and it com in a shape of a plate, as shown in Figure 2. All dimensions in the figures are in mm. omes .70 50 30 600 -75-> 145 Figure 1 Figure 2 At your disposal are: (1) a rolling mill, (2) a shearing machine, (3) a blanking machine, and (4) a deep drawing machine with a die corner radius of 5 mm. The rolling mill's specifications are as follow: • Type of rolling mill: 2-high reversing mill for flat rolling • Roll radius = 800 mm • Roll rotational speed = 70 rev/min • Coefficient of friction between rolls and work = 0.13 In case of multiple passes, the draft is equal for each pass. .
Required You are required to analyze and design a complete manufacturing process (set of manufacturing processes) which can be applied to manufacture the cup by using the available machines. Ignore any change in thickness of the blank during deep drawing. The requirements of each manufacturing steps are as follows: Rolling: Assume that you have a 2-high mill for flat rolling; and find the following: • Determine the number of rolling passes required, and the draft for each pass. • Determine the rolling force, the rolling torque, and the rolling power. • At what temperature you prefer to do this process and why? • Assuming no change in width during rolling, what is the final length of the rolled sheet? . Shearing • What clearance must be allowed in the shearing operation? • Determine the shearing force to cut a square piece out of the rolled sheet. • What are the dimensions of the sheared sheet? • How many square pieces can be sheared out of the rolled sheet? Blanking • Determine the blanking force • Determine the blanking punch diameter • Determine the blanking die diameter Deep Drawing • Determine the punch diameter, and the die cavity diameter • Is the deep drawing operation feasible? • Determine the drawing force. • Determine the holding force, Fh. .
Overall • How many cups can you manufacture by using the given starting plate? • Do you expect any defect in the manufactured cup? Why? —D— Volume of cup = volume of base or disc + volume of the upper hollow cylinder Table 1.1. Values of n and K for some alloys Alloy Copper (annealed) n 2024-T3 Naval brass Low carbon steel 304 stainless 4340 alloy Al alloy (annealed) (annealed) steel steel 0.17 0.21 0.44 0.12 780 600 1400 2650 0.21 0.44 к (MPa) 585 530 Table 1.2 Material Stainless steel (half 2024ST and 6061ST AL 1100S and 50528 hard and full hard), alloys; brass, soft CR Al alloys, all CR steel (half hard) steel, soft stainless steel tempers 0.075 0.06 0.045 Clearance allowance