A sheet metal blank is 400 mm long × 200 mm wide and has plain semicircular ends with radius 100 mm. The space between the blanks and the edges is 30 mm. It is proposed that 500,000 parts should be manufactured using 16 gage low carbon steel. Assuming the worker rate is $40/hr,

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Q1. (30 points, 10 points each) During a tensile test, the following data was found on an aluminum alloy (6082-T6) bars (3/4” in diameter and 3” in length):

Young’s Modulus (GPa)	70
Yield Stress (MPa)	240
Tensile Stress (MPa)	280
Strain to Failure (%)	11

According to these data,

What is the elastic strain of this particular type of the aluminum?
What is the elastic energy that can be stored in this particular type of the aluminum?
For a sheet metal that is made from the same aluminum alloy, if the thickness is 5 mm, what is the minimum bending radius?

Answers:

Q2. (50 points, 25 points each) A sheet metal blank is 400 mm long × 200 mm wide and has plain semicircular ends with radius 100 mm. The space between the blanks and the edges is 30 mm. It is proposed that 500,000 parts should be manufactured using 16 gage low carbon steel. Assuming the worker rate is $40/hr,

(a) Estimate the cost of a blanking die to produce the part.

(b) What is the percentage of manufactured scrap that would result from the blanking operation?

(Hint: Please provide graphical proof of the estimation during the work.)

Answers:

Q3. (20 points) The part shown below is produced from a flat blank 86 cm long by 54 cm wide. Determine the die cost if the total length of the bend lines is 102 cm. Use $40/hr for the worker rate.

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