A sheet metal blank shown in the Figure is done through a part-off die. During the...

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A sheet metal blank shown in the Figure is done through a part-off die. During the shearing process, a 25 mm distance is allowed for securing the sides of the sheet metals on the die blocks and installation of strip guides. As a design engineer, you propose the follow estimations to manufacture 50,000 parts using 16-gauge low carbon steel with a die plate thickness (hp) of 28.4 mm. (a) A part-off die is used to blank a scrap weighting of 0.2 kg. Each shearing process produces a scrape from the 16- gauge low carbon steel sheet metal. If the energy required to punch a scarp is 4 J/m3, how many scraps/blanks can you produce from a brand-new cutter of 5 kg moving at a speed of 1 cm/s? Assuming the density of the stainless steel is 7900 kg/m3, and the cutting tool dulls at a linear rate of 0.001% of its original condition (i.e., dulls at the percentage of brand-new condition, not the previous blanking condition) (15 points). (b) Use the following information to estimate the blanking die cost to produce 50,000 parts. Length: 400 mm; Width: 200 mm; Perimeter: 1415 mm; Worker Rate: $40/hr (25 points). (Hint: Please determine the area correction factor use the plot provided.) (c) Determine the percentage of manufactured scrap if the part area is 784 cm2 (10 points). Scrap A sheet metal blank shown in the Figure is done through a part-off die. During the shearing process, a 25 mm distance is allowed for securing the sides of the sheet metals on the die blocks and installation of strip guides. As a design engineer, you propose the follow estimations to manufacture 50,000 parts using 16-gauge low carbon steel with a die plate thickness (hp) of 28.4 mm. (a) A part-off die is used to blank a scrap weighting of 0.2 kg. Each shearing process produces a scrape from the 16- gauge low carbon steel sheet metal. If the energy required to punch a scarp is 4 J/m3, how many scraps/blanks can you produce from a brand-new cutter of 5 kg moving at a speed of 1 cm/s? Assuming the density of the stainless steel is 7900 kg/m3, and the cutting tool dulls at a linear rate of 0.001% of its original condition (i.e., dulls at the percentage of brand-new condition, not the previous blanking condition) (15 points). (b) Use the following information to estimate the blanking die cost to produce 50,000 parts. Length: 400 mm; Width: 200 mm; Perimeter: 1415 mm; Worker Rate: $40/hr (25 points). (Hint: Please determine the area correction factor use the plot provided.) (c) Determine the percentage of manufactured scrap if the part area is 784 cm2 (10 points). Scrap