BIOENGINEERING AND AEROSPACE

AEROSPACE DESIGN II
ENGINEERING DEPARTMENT

EXAM June 16th

Name: Surname:

NIA: Group:

PROBLEM 1:

A manufacturing company has an order to manufacture 10.000 brackets (see figure 1). A
steel strip with an ultimate tensile stress of B=56 Kg/mm2 and 2 mm thickness will be
used as raw material.

Figure 1
The company has the intention of using a press for the shearing process with the following
curve Force/ram position:

The piece will be manufactured in two phases:

1. Shearing process.
2. Bending process.

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BIOENGINEERING AND AEROSPACE
AEROSPACE DESIGN II
ENGINEERING DEPARTMENT

SHEARING PROCESS:
The shearing process is performed in a compound die.
1) Indicate and justify the type of press (attending to the power source) that suit
better for this process. (0.25 points)
2) Obtain the minimum strip width required to manufacture the piece .Assume that
the shortest side of the piece (30mm) is oriented in the feed direction and the neutral axis
is positioned in the middle point of the thickness. (0.25 points)
3) Indicate if the preselected press can be used for this shearing process (inner and
outer cuts) and draw roughly a sketch of the punch used in the process (including the
main dimension). (0.4 points)
4) Calculate the work developed by the press during the shearing process (X=0.8).
(0.25 points)
5) Indicate the minimum surface dimensions of the die, draw roughly the strip design
and describe the process to manufacture the piece. (0.5 points)
6) Considering a new scenario in which the production of brackets increases (tending
to mass production), would it be possible changing the type of die in order to increase the
rate of production (the design changes can not involve new strip width), justify and list the
changes. If in this new scenario there were not any limitation in the type of die and strip
width, list and justify changes to improve the rate of production. (1 points)

BENDING PROCESS:
This process is carry out in a bending machine in which there is a die with “die-opening
dimension” of 32 mm.
7) Obtain the bending force assuming that k = 1.2 (consider a value of the yield point
equal to the ultimate tensile stress of this material). (0.5 points)
8) Obtain the work involve in this process assuming corrector factor for the force
equal to 0.8. (0.25 points)

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