Assignment on Sheet-Forming Processes

Attempted any 40 questions, your answer should short with suitable diagram, you
need to submit your assignment till 8/6/2020, after submission we will have
interactive discussion on this assignment if required. Write your assignment write
page number along with your signature on every page and mail it to me before
deadline.

1. What distinguishes sheet forming from bulk forming?

2. What is a definition of shearing?
3. Why are sheared or blanked edges generally not smooth? What are the various regions
on a sheared edge?
4. What measures can be employed to improve the quality of a sheared edge?
5. How does fine blanking create shearing in a compressive environment?
6. Why are fine blanking presses more complex than those used in conventional blanking?
7. Why might a long shearing cut be made in a progressive fashion like cutting with
scissors?
8. What is a slitting operation?
9. What are the differences between piercing and blanking?
10. What are some types of blanking or piercing operations that have come to acquire
specific names?
11. What are the basic components of a piercing or blanking die set?
12. What is the purpose of having a shear angle or rake angle on a punch?
13. Why is it important that a blanking punch and die be in proper alignment?
14. What is the major benefit of mounting punches and dies on independent die sets?
15. What is the major benefit of assembling a complex die set from standard suppress dies?
16. What is the benefit of making dies as a multiplies assembly?
17. What is a ‘‘steel-rule die,’’ and for what types of designs and materials is it used?
18. What is a progressive die set?
19. What is the difference between progressive dies and transfer dies?
20. How do compound dies differ from progressive dies?
21. What is the attractive feature of a turret-type punch press?
22. When making bends in sheet metal, what is the distinction among bending, forming,
and drawing?
23. What are the stress states on the exterior surface and interior surface of a bend?
24. Why does a metal usually become thinner in the region of a bend?
25. What is spring back, and why is it a concern during bending?
26. Why is spring back an increased concern for the newer advanced high-strength steels?
27. What types of operations can be performed on a press brake?
28. What factors determine the minimum bend radius for a material?
29. If a right-angle bend is to be made in a cold-rolled sheet, should it be made with the
bend lying along or perpendicular to the direction of previous rolling?
30. From a manufacturing viewpoint, why is it desirable for all bends in a product (or
component) to have the same radius?
31. What is the difference between air-bend and bottoming dies? Which is more flexible?
Which produces more reproducible bends?
32. What is the primary benefit of incorporating a coining action in bottom bending? The
primary negative feature?
33. Why are different types of presses (mechanical and hydraulic) used in bottom bending
and air bending?
34. What is the benefit of using a urethane (rubber) bottom die in bending operations?
35. What type of products are produced by roll bending?
36. What is the role of the form block in draw bending and compression bending?
37. How can flattening or wrinkling be prevented when bending a tube?
38. What type of product geometry can be produced by cold-roll forming?
39. Is the roll forming process appropriate for making short lengths of specialized
products?
40. What are some methods for straightening or flattening rod or sheet?
41. What two distinctly different metal forming processes use the term ‘‘drawing’’?
42. What is the difference between drawing and stretching?
43. Why is the tooling cost for a spinning operation relatively low?
44. What is the benefit of the laser assist in laser-assisted metal spinning?
45. How is shear forming different from spinning?
46. For what types of products would stretch forming be an appropriate manufacturing
technique?
47. What is the distinction between shallow drawing and deep drawing?
48. What is the function of the pressure ring or hold-down in a deep-drawing operation?
49. What are the key variables in a deep-drawing operation?
50. Explain why thin material may be difficult to draw into a defect-free cup.
51. How can redraw operations be used to produce a taller, smaller-diameter cup than can
be produced in a single, deep drawing operation?
52. What are draw beads, and what function do they perform?
53. Why is a trimming operation often included in a deep drawing manufacturing
sequence?
54. How does the Guerin process reduce the cost of tooling in a drawing operation?
55. How can fluid pressure or rubber tooling be used to perform bulging?
56. What is sheet hydroforming?
57. What are the various forms of sheet hydroforming?
58. What explanation can be given for the greater formability observed during sheet
hydroforming? How is this feature being used in the automotive industry?
59. What is the purpose of the inward movement of the end plugs during tube
hydroforming?
60. What is the difference between low-pressure tube hydroforming and high-pressure
tube hydroforming in terms of both pressures and the nature of the deformations
produced?
61. What is the advantage of hot-metal-gas-forming over conventional tube hydroforming?
62. What are some of the basic methods that have been used to achieve the high energy-
release rates needed in the HERF processes?
63. Why is spring back rather minimal in high-energy-rate forming?
64. What are some well-known products that have been produced by processes including
ironing by embossing?
65. What material and process conditions are associated with superplastic forming?
66. What is the major limitation of the superplastic forming of sheet metal? What are some
of the more attractive features?
67. What properties from a uniaxial tensile test can be used to assess sheet metal
formability?
68. How is the formability in biaxial tension different from that in uniaxial tension?
69. What techniques can be used to assess ‘‘normal anisotropy’’ and ‘‘planar anisotropy’’ in
sheet material?
70. How can strain analysis be used to determine locations of possible defects or failure in
sheet metal components?
71. What is a forming limit diagram?
72. Explain the key difference between the right- and left-hand sections of a forming limit
diagram. These sections correspond to stretching and drawing.
73. Describe two alternative methods of producing complex shaped thin products without
requiring sheet metal deformation techniques.
74. What two hot-forming operations can be used to produce pipe from steel strip?
75. What features should be considered when selecting a press for a given application?
76. What are the primary assets and limitations of mechanical press drives? Of hydraulic
drives?
77. What are some of the common types of press frames?
78. What is the purpose of inclining or tilting a press?
79. Describe how multiple operations are performed simultaneously in a transfer press.
80. What types of products are produced on a four-slide or multi slide machine?