ASSGNMENT 1- DESIGN FOR SHEET METAL FORMING

Name: MOHD ZAHID BIN HALIM

No Id : 54213119193
Date : 2/9/2021

1. What typically is done to make sure that the product in flat rolling is not crowned?
To make sure that the product in flat rolling is not unreasonably crowned, a number of strategies
can be followed, which basically compensate for roll bending. These include

 The use of backing rolls.

 Using crowned rollers so that roll deflections are compensated by the geometry of the roller
to produce a flat workpiece.
 Superimposing a deflection on the rolls by bending them; the elastic deformation of the
rollers is then compensated by the deflection from the bending moment.
 Using a front and/or back tension to reduce the rolling pressure, and hence the force on the
rolls.

2. List the possible consequences of rolling at (a) too high of a speed and (b) too low of a
speed.
 (a) too high of a speed
Rolling at a high speed is advantageous because the production rate is increased, but it has
disadvantages, including:

 the lubricant film thickness entrained will be larger, which will reduce friction and lead to
the rolls slipping against the workpiece. This condition can cause the surface finish of
the workpiece to be damaged.
 chatter may occur, which will compromise the surface quality or process viability
(b) too low of a speed.
Rolling at a low speed is advantageous because the surface roughness of the strip can match
that of the rolls, but it has disadvantages, including:

 low production rate, and thus higher cost

 there may be a danger of transferring material from the workpiece to the roll (pickup)
because a sufficiently thick lubricant film can't be developed and maintained, thus
damaging surface finish.
 slow rolling will cause the workpiece to lose some of its heat to the environment and to
the roller conveyer.
3. Explain why cupping tests may not predict well the formability of sheet metals in
actual forming processes.

 In a cupping test, the material is deformed the same in all directions. However, sheet
metal forming rarely happens on every axis simultaneously, thus the metal experiences
different strain rates during forming. Because the test is easy to do and can give a
relative indication of how well a metal will deform compared to others, it is still useful.

4. Explain the differences that you have observed between products made of sheet
metals and those made by casting and forging.

 The most obvious difference between sheet-metal parts and those that are forged, or
cast is the difference in cross-section or thickness. Sheet-metal parts typically have large
surface area-to-thickness ratios and are less stiff, hence easier to distort or flex. Sheet-
metal parts are rarely for structural uses unless they are loaded in pure tension because
they otherwise would buckle at relatively low compressive loads. Sheet-metal parts
generally have a smoother surface than forgings or casting unless a finishing operation
has been performed. Forged and cast parts can be subjected to various combinations of
loads.