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Sheet Metal Forming Design Exercise

This document provides instructions for two exercises in sheet metal forming part design. Exercise 1 involves designing a cylindrical cup from mild steel sheet and calculating the blank diameter and drawing force. Exercise 2 involves designing a T-bracket component from galvanized steel and evaluating hole dimensions and spacing. Key details include: 1) For the cylindrical cup, the formula for blank diameter is given to calculate the required 102mm external diameter. Drawing ratio and tensile stress are also given to calculate the overall drawing force. 2) For the T-bracket, stamping processes and a minimum force calculation are required based on the ultimate tensile stress of galvanized steel. Hole dimension and spacing must also be

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76 views2 pages

Sheet Metal Forming Design Exercise

This document provides instructions for two exercises in sheet metal forming part design. Exercise 1 involves designing a cylindrical cup from mild steel sheet and calculating the blank diameter and drawing force. Exercise 2 involves designing a T-bracket component from galvanized steel and evaluating hole dimensions and spacing. Key details include: 1) For the cylindrical cup, the formula for blank diameter is given to calculate the required 102mm external diameter. Drawing ratio and tensile stress are also given to calculate the overall drawing force. 2) For the T-bracket, stamping processes and a minimum force calculation are required based on the ultimate tensile stress of galvanized steel. Hole dimension and spacing must also be

Uploaded by

虎徹
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

 

ISE386 Integrated Design for Manufacture


Exercise 1: Sheet Metal Forming Part Design (Total 20 marks)

1. A mild steel sheet of 2.0 mm thickness is required to form a cylindrical cup having an external
diameter of 102 mm and overall height of 41 mm as well as a thickness of 2 mm.

Sectional view
Figure 1a cylindrical cup of made of a mild steel sheet.

(a) Deduce the formula of estimating the blank diameter so as to achieve Do = √4 .


(5 marks)

(b) The relevant drawing ratio (DR) of such material is 1.75. Using the deduced formula to
evaluate the overall drawing force to transform the blank into the final shape of this cup.
Assuming the tensile stress (σs) of the material is 320 N/mm2. (5 marks)

Given:
The blank diameter of cup Do = √4 ;
where d is the external diameter and h is the inner height of the cup.

Drawing force for transformation F = ;

where t is the material thickness and c is the material constant = 0.675.

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2. Consider a T-bracket component made of Galvanized Steel (GS) as shown in the Figure 2. You
are asked to produce a large batch of such component.

Figure 2 A T-bracket component made of GS.

(a) Suggest only 2 stamping processes with related sketches for explanation, if required.
(2 marks)

(b) What is the minimum force needed for producing the outer profile of the T-bracket component
(ignore those inside holes) if the ultimate tensile stress of GS is 150 N/mm2?         (2 marks)

(c) Based on this part design, briefly comment on the hole dimension Ø1.8 mm and distance apart
of holes with Ø8 mm from their edges. (6 marks)

Note: Please be reminded to submit your assignments with free-hand sketches or CAD drawings in
printed format on A4 papers.
The assignment should be submitted on or before 20th March 2019 via the pigeon box of Prof.
Chan at 6/F or EF601 or General office (EF625), marks will be deducted for any late submission
of assignment.

2 
 

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