Dr.
VIJAYA KUMAR K
M. Tech (NITK), Ph.D.
GATE Trainer. METAL FORMING +919652805628
SHEET METAL OPERATIONS.
Punching And Blanking.
1. A washer of 28.4 mm outer diameter and 14.7 mm inner hole is to be made from a 1.6mm
thick strip of 0.2% carbon steel; Consider Clearance is 3% of the thickness.
(ii) Die and Punch size blanking Operation
(ii) Die and Punch Size Punching Operation.
2. A blank of 50mm diameter is to be sheared from a sheet of 2.5mm thickness. The required
radial clearance between the die and the punch is 6% of sheet thickness. The punch and die
diameter (in mm) for this blanking operation, respectively, are ______________
(a) 50.00 and 50.30 (b) 50.00 and 50.15
(c) 49.70 and 50.00 (d) none
3. A disc of 200mm diameter is blanked from a strip of an aluminium alloy with a thickness
of 3.2mm. The material shear strength to fracture is 150MPa. The blanking force (in KN) is __
(a) 291 (b) 301 (c) 311 (d) 421
4. Common Data for Questions i, ii & iii
The part shown in fig is to be blanked from a steel strip of 2 mm thickness. Assuming the
penetration to be 40% and the ultimate shear strength of the material to 145 MPa,
(i) The force required for the blanking operation would be.
(ii) Work done in blanking operation would be
(iii)The shear to be provided to carry out this operation on a 24 kN press is............
5. The ratio of press force required to punch a square hole of 30 mm side in a 1 mm thick
aluminium sheet to that needed to punch a square hole of 60 mm side in a 2 mm thick aluminium
sheet is _________________
6. The force requirement in a blanking operation of a low-carbon steel sheet is 5.0 kN. The
thickness of the sheet is 't', and the diameter of the blanked part is 'd'. For the same work material,
if the diameter of the blanked part is increased to 1.5d and the thickness is reduced to 0.4t, the
blanking force in kN is the new
(a) 3.0 (b) 4.5 (c) 5.0 (d) 8.0
7. 26.7 mm diameter holes are to be punched in a steel sheet of 3 mm thickness. The
material's shear strength is 400 N/mm², and penetration is 40%. The shear provided on the punch is
2 mm. The blanking force during the operation will be
(a) 22.6 kN (b) 37.7 kN (c) 61.6 kN (d) 94.3 kN
8. In punching a circular hole of size 50 mm diameter in a sheet of thickness 6 mm with a clearance
of 10% and shear strength of sheet metal is 477.5 MPa. If a shear of 3 mm is provided on the
Punch, the force required is reduced to 200 kN, and the penetration of material is
percentage_______________
(a) 25% (b) 30% (c) 35% (d) 40%
9. A hole of 40mm diameter is pierced in a steel sheet of 4mm thickness without shear on the
tool. The shear strength of steel is 400 N/mm², and penetration is 25%. What is the expected
percentage load reduction if a shear of 1mm is provided on the punch?
(a) 25.00 (b) 33.33 (c) 50.00 (d) 66.67
10. A washer has a 12.7mm hole and an outside diameter of 25.4mm. it is 1.25 mm thick and
made of SAE 1020 steel, having a shear strength of 800MPa if the radial clearance is taken as
0.04mm.
(i) The piercing punch and die opening size are _____________
(a) 12.7 & 25.4 (b) 12.7 & 12.78 (c) 12.78 & 12.7 (d) 12.78 & 25.48
(ii) The blanking die opening size and blanking die punch size is ___________
(a) 25.4 & 25.32 (b) 25.32 & 25.4 (c) 25.48 & 25.32 (d) 25.4 & 25.4
11. What force is required by the punch to shear out the blank (form a circular disc) of 20 mm
diameter and 1.5 mm thickness and having a shear strength equal to 300 MPa ?
(a) 9.0 kN (b) 18.0 kN (c) 28.3 kN (d) 45.0 kN
12. A punch is used for making holes in steel plates with a thickness of 8 mm. If the punch
diameter is 20 mm and force required for creating a hole is 110 kN, the average shear stress in the
plate will be nearly ________________
(a) 139 MPa (b) 219 MPa (c) 336 MPa (d) 416 MPa
13. In a sheet metal of 2 mm thickness, a hole of 10 mm diameter needs to be punched. The yield
strength in tension of the sheet material is 100 MPa, and its ultimate shear strength is 80 MPa. The
force required to punch the hole (in kN) is _______ [GATE ME-2016]
14. Find the blanking force required to punch 10 mm diameter holes in a steel sheet of 3 mm
thickness. Given the shear strength of material = 400 MPa, penetration = 40% and shear provided
on the punch = 2 mm.
(a) 22.6 kN (b) 37.7 kN (c) 61.6 kN (d) 94.3 kN
15. The percentage scrap in a sheet metal blanking operation of a continuous strip of sheet metal, as
shown in the figure, is _____________(correct to two decimal places).
[GATE ME-2018]
16. A sheet metal with a stock hardness of 250 HRC has to be sheared using a punch and a die
with a clearance of 1 mm between them. If the stock hardness of the sheet metal increases to 400
HRC, the clearance between the punch and the die should be mm.______ [GATE ME-2020]
17. Ignoring the small elastic region, the true stress (𝜎) – true strain (𝜀) variation of a material
beyond yielding follows the equation 𝜎 = 400𝜀0.3 MPa. The engineering ultimate tensile strength
value of this material is ________ MPa. [GATE ME-2023]
18. A blanking operation is performed on C20 steel sheet to obtain a circular disc having a
diameter of 20 mm and a thickness of 2 mm. An allowance of 0.04 is provided. The punch size used
for the operation is ___________ mm (rounded off to 2 decimal places) [GATE ME-2024]
Deep Drawing Operation.
1. A cup of diameter of 30mm and height of 150mm is to be produced with a negligible corner
radius DR1=1.6 DR2 and above 1.8; determine the number of draws required the operation
n=________ (ANS: 3)
2. A cup of a diameter of 30mm and height of 150mm is to be produced with a negligible corner
radius DRR1=40% DR2 and above 25%; determine the number of draws required the operation
n=________ (ANS: 5)
3. A cup 5cm in diameter and 7.5cm deep is to be drawn from 1.5mm thick drawing steel with
a tensile yield strength of 315MPa. The corner radius is negligible.
(i) The least number of drawing operations with a draw ratio of 1.8 is _____________
(a) 1 (b) 2 (c) 3 (d) 4 (ANS: b)
(ii) The force and energy for the first draw with a draw ratio of 1.8 and neglect friction, bend, and
blank holding force is ___________ (ANS: a)
(a) 197 kN & 8 kJ (b) 8kN & 197 kJ (c) 197 kJ & 8 kN (d) none
4. A cylindrical cup of diameter 12mm & height 16 mm has a corner radius of 0.5 mm is made
out of a sheet of 2mm thick & the material has a constant flow of 35MPa. Neglecting the corner
radius, ______________
(ii) The number of draws required is part of the draw reduction ratio for first and subsequent draws
is 40%, and 25% is ________________ (ANS: b)
(a) 2 (b) 3 (c) 4 (d) 5
(ii) The drawing stress for the first draw based on idle deformation (neglecting friction, blank holding
force & effect of punch corner radii is _______________ (ANS: b)
5. A circular cup of 100mm outside diameter & 25mm height is to be drawn from an aluminium
sheet of 1 mm thickness. The corner radius of a cup is 6 mm. Assuming a trimming allowance of 3
mm, the diameter of the blank required is _______________ (ANS: 144.12mm)
6. A cup of 50 mm diameter and 80 mm height with a flange diameter of 100 mm is to be
produced from a sheet of 1 mm thick and yield strength of 100 MPa. The energy required for the
first draw with the draw ratio of 2 is (neglecting friction, bending and blank holder force) _______
(a) 3063 J (b) 3063 kJ (c) 3063 MJ (d) 3063 GJ
(ANS: a)
7. A shell of 100 mm diameter and 100 mm height with a corner radius of 0.4 mm will be
produced by cup drawing. The required blank diameter is____________ (ANS: c)
(a) 118 mm (b) 161 mm (c) 224 mm (d) 312 mm
8. During the bending of a medium carbon steel sheet of thickness 3mm, the percentage
reduction in area during a tensile test at the time of fracture is 12.5%. the minimum radius to which
the sheet can be bent is__________________ (ANS: b)
(a) 12 mm (b) 9 mm (c) 6mm (d) 3mm
9. A cup 5cm in diameter and 7.5cm deep is to be drawn from 1.5mm thick drawing steel with
a tensile yield strength of 315MPa. The corner radius is negligible.
The blank diameter is ____________ (ANS: c)
(a) 10 cm (b) 12.5 cm (c) 13.2 cm (d) 14.8 cm
10. A cylindrical cup of diameter 12mm & height of 16 mm has a corner radius of 0.5 mm, made
out of a sheet 2mm thick & the material has a constant flow of 35MPa. Neglecting the corner radius,
The diameter of the blank would be _________________ (ANS: b)
(a) 20 mm (b) 30.2 mm (c) 36.1 mm (d) 41.6 mm
11. A cup is shown if the fig is to be drawn from a low carbon steel thickness of 0.8mm. The
edge trimming allowance is to be provided 4mm on radius. Neglecting corner radius, thinning &
spring back. the diameter of the blank required is_______________________ (ANS:100mm)
12. A press working operation forms a hemispherical cup of radius 'R'. The radius of the blank
would be ________________ (ANS: a)
(a) √2 R (b) √3 R (c) √2 /3R (d) √3/2 R
BENDING:
13. The end view of a drawing board clip is shown in Fig. below. The width of the clip is 20 mm.
The length of flat starting strip is ________________
14. A 2mm thick metal sheet is to be bent at an angle of one radian with a bend radius of
100mm. If the stretch factor is 0.5, the bend allowance is ____________
a) 99mm b) 100mm c) 101mm d) 102mm
15. Find the length of the bend component shown in the figure below ___________
(ANS:466.245)
Punching and blanking Questions.
A washer has a 12.7mm hole and an outside diameter of 25.4mm. it is 1.25 mm thick and made by
SAE 1020 steel having shear strength of 800MPa. If the radial clearance is taken as 0.04mm.
(i) The piercing punch size and the piercing die opening size are _________
(a) 12.7 & 25.4 (b) 12.7 & 12.78 (c) 12.78 & 12.7 (d) 12.78 & 25.48
(ii) The blanking die opening size, and blanking die punch size is ___________
(a) 25.4 & 25.32 (b) 25.32 & 25.4 (c) 25.48 & 25.32 (d) 25.4 & 25.4
(iii) The force required if compound die is used. Take clearance as 0.04mm ________
(a) 40 kN (b) 120 kN (c) 80 kN (d) 200 kN
(iv) If the progressive die system is used with staggering of punches, the max force required____
(a) 40 kN (b) 120 kN (c) 80 kN (d) 200 kN
(v) Assume 60% penetration for steel and shear for both provided as 1mm, the force needed if both
punches act together in progressive die working is ___________
(a) 40 kN (b) 51.5 kN (c) 63.25 kN (d) none
