Question

Q1) Figure 1. A sheet metal with a hole punched in it a) In Figure 1, what is the rough edge (highlighted within yellow dashed circle) called as and why is it formed? (10 points) (minimum 5 bullet points) firmy Figure 2. Thin metal parts with intricate profiles cut into it b) What advanced machining process is used to form the parts shown in Figure 2. Briefly explain the process? (15) [minimum 7 bullet points) c) With a rough sketch and appropriate notations, explain the principles of merchant circle for calculating the cutting forces? Why is it important to quantify the cutting forces (25 points)? [minimum 10 bullet points]

Answer 1

Ans-1

The rough edge shown in yellow dashed circle is called as 'burr' and it's a defect of sheet metal operation.

Why burr is formed-

Reasons-

1. Due to operators lack of awareness the part is not located at it's specified location and burr formation takes place due damage of edges of the punch.

2. Due to lack of skills of an operator caused by improper training of operator.

3. Due to improper part handling methods used by operator

4. Due to the inadequate clearance provided between die and punch . The clearance is depends on the thickness of the plate. And the clearance and thickness provision should be proper otherwise proper shearing and breakage will not take place.

5. Press machine misalignment can also cause the burr.

Answer 2

idk so please tell me