04-01: The Review Questions for Basics of Sheet

Metalworking

KAINAT ALTAF
IE-16-12
1.Transcribe the Video ‘VTS_18_01’.
2. Make a tabular comparison of the similarities and the dissimilarities between
the bulk forming processes and the sheet-forming processes.
3. Give at least ten examples of parts that you think are made of metal sheet or
plate (other than given in slides). Make a 4-column table as: column 1, serial
number; column 2, part name; columnn3, part picture; column 4, part usage.

Serial Part Name Part Picture Part Use

Number
1 Roof Sheet Use in Warehouses
as Color Coated
Roof Sheet.

2 Cabinet Sheet Fabrication

for Network Cabinet

3 Doors Automobile doors

4 Telecom Electric Purposes

Cabinet
 5 Kitchen For different
Utensils purposes in Kitchen.

6 Hinge For Support in

Doors

7 Door Handle Help in Open and

Close of door

8 Housings For Home as well

industrial use.

4. How can sheet metalworking operations be classified? Discuss briefly.

Ans. The three basic types of sheet metalworking operations are

(1) Cutting
(2) Bending
(3) Drawing
Cutting is used to separate large sheets into smaller pieces, to cut out part perimeters, and to
make holes in parts.
Bending is a process in which the metal is deform in such a way that the length and thickness
before bending and after bending remains same. It only changes shape of the work piece.
Deep drawing is a process of converting metal sheet into cylindrical or box shaped structure
with or without changing its length and thickness.
Many cylindrical parts like metal can, pots, container for food and beverages, kitchen sinks,
automobile fuel tank etc. are deep drawing product.

https://www.mech4study.com/2017/05/what-is-deep-drawing-process.html
5. What are different ways of
classifying stamping Presses?
Ans. Presses are available in a variety of
a) Capacities
b) Power systems
c) Frame types
The capacity of a press is its ability to deliver the required force and energy to accomplish the
stamping operation. This is determined by the physical size of the press and by its power
system.
The power system refers to whether mechanical or hydraulic power is used and the
type of drive used to transmit the power to the ram. Production rate is another important
aspect of capacity.
Type of frame refers to the physical construction of the press. There are two
frame types in common use: gap frame and straight-sided frame .

Fundamentals of modern Manufacturing, edition 4, Mikell P. Groover

6. How does a mechanical press work?

Ans.
There are various components that mechanical presses use to perform work. The major ones
include drives, drive motors, flywheels, clutches, and breaks.
There are several types of drives a press can use. They include press, shaft, blankholder, knuckle
joint, linkage, and eccentric or crank drives. Each has its own uses and advantages.
Drive motors power the main drive system. Flywheels store this energy and provide it to the
rest of the machine.
Clutches move the torque produced by the drive and flywheel to the gear shaft. Brakes activate
when the clutch is released, slowing and/or stopping the other components.

Fundamentals of modern Manufacturing, edition 4, Mikell P. Groover

7. Make a sketch of a C-frame press by hand and label all parts. Briefly explain
the function of major parts.
Ans.
A flywheel is used to store the energy of the drive motor for use in the stamping operation.
Bed support the whole structure while bolster plate support the die.
The relative positions of the bed and ram are established by the frame, and the ram is driven by
mechanical or hydraulic power. When a die is mounted in the press, the punch holder is
attached to the ram, and the die holder is attached to a bolster plate of the press bed.

Fundamentals of modern Manufacturing, edition 4, Mikell P. Groover

8. What is the difference between single-, double-, and triple-action press?

When are the double and triple-action presses particularly used?
Ans.
Single Action:
Any press with a single slide and usually considered to be without any other motion or pressure
device which would affect the press working on the part.
Double Action:
A mechanical press having two independent parallel movements of two mechanical press
slides. More suitable for drawing especially deep drawing.
Triple Action:
A mechanical press having three independent parallel movements of two mechanical press
slides. They are particularly used for parts that require drawing in two directions. The third
action of the press can draw the reverse shape while the blank holder and upper punch dwell.

https://www.aida-global.com/metalforming-resources/metalforming-glossary/
Handbook of Fabrication Process

9. What is a press brake?

Ans. The friction mechanism used to stop or control the motion of a press, feed or other
mechanism.
https://www.aida-global.com/metalforming-resources/metalforming-glossary/

10. What are die sets used for? Show main parts of a two-post die set.

Ans. Die set include punch holder , punch, Die holder , die, guide pins, bushings and flanges.
Each part has its own function. Overall die set support the die and workpiece during sheet metalworking
process.

04-01 Lec18 Sheet Metalworking Basics...._20200318_194124401.pdf

12. What is meant by tonnage of a press? How is tonnage for a mechanical and
hydraulic press found?
Ans. The force that the press is designed to exert against the work piece in the die.
 The tonnage of a hydraulic press is the piston area multiplied by the oil pressure in the cylinder.
 The tonnage of a mechanical press is approximately equal to the shear strength of the
crankshaft metal multiplied by the area of crankshaft bearings.

www.production-resources.com/pdfs/PRI-formulas.pdf

13. What is the difference between the stroke and the shut height of a press?
Ans.
Stroke:
The reciprocating motion of a press slide, usually specified as the number of inches between
the terminal points of the motion.
Shut Height
The shut height of an upright press is the distance from the top of the bed to the bottom of the
slide with stroke down and adjustment up. The shut height must always be defined either from
the top of the bed or from the top of the bolster. The shut height of a horizontal or inverted
press, or of a press with adjustable bed, can be defined in a similar manner. Generally the shut
height is equal to the maximum die-height of the die that can be accommodated, taking the
bolster into consideration.

14. How is the shut height of a die set defined?

Ans. The shut height is the outside dimension of the die set (measured from the bottom to the
top die plate) when the press ram is at the limit of its downward stroke (in the case of a vertical
press).