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Assignment One (Metal Forming Processes)

This document contains 6 questions regarding metal forming processes. Question 1 asks to calculate various metrics related to direct extrusion such as extrusion ratio and ram pressure. Question 2 asks to briefly describe 7 metal forming processes including rolling, drawing, deep drawing, bending, forging, extrusion, and stretch forming. Question 3 asks to show that the maximum thickness reduction, Δhmax, equals μ2R using the provided sketch. Question 4 asks to calculate roll force and power for rolling and determines feasibility of a multi-pass cold rolling operation. Question 5 asks to calculate the forging force for a single-pass open die forging operation. Question 6 asks to calculate the force at various heights during a warm upset forging operation.

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188 views

Assignment One (Metal Forming Processes)

This document contains 6 questions regarding metal forming processes. Question 1 asks to calculate various metrics related to direct extrusion such as extrusion ratio and ram pressure. Question 2 asks to briefly describe 7 metal forming processes including rolling, drawing, deep drawing, bending, forging, extrusion, and stretch forming. Question 3 asks to show that the maximum thickness reduction, Δhmax, equals μ2R using the provided sketch. Question 4 asks to calculate roll force and power for rolling and determines feasibility of a multi-pass cold rolling operation. Question 5 asks to calculate the forging force for a single-pass open die forging operation. Question 6 asks to calculate the force at various heights during a warm upset forging operation.

Uploaded by

Anonymous XybLZf
Copyright
© © All Rights Reserved
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Download as DOCX, PDF, TXT or read online on Scribd
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Due Date: 30 September 2016

Assignment One
A billet that is 75 mm long with diameter = 35 mm is direct extruded to a diameter of 20 mm. The
extrusion die has a die angle = 75. For the work metal, K = 600 MPa and n = 0.25. In the Johnson
extrusion strain equation, a = 0.8 and b = 1.4. Determine (a) extrusion ratio, (b) true strain
(homogeneous deformation), (c) extrusion strain, (d) ram pressure (e ) ram force
[25]
Question Two
With the aid of neat sketches, briefly describe the following metal forming processes,
i.
ii.
iii.
iv.
v.
vi.
vii.

Rolling (hot and cold)


Drawing
Deep drawing
Bending
Forging
Extrusion
Stretch forming

[5]
[5]
[5]
[5]
[5]
[5]
[5]

Question Three

Using the sketch shown in Fig.3 above, show that hmax = 2R

[10]

Question Four
a. An annealed copper strip 228mm wide and 25mm thick is rolledto thickness of 20mm.
The radius of the roll is 300mm and it rotates at 100rpm. Calculate the roll force and the
power for this operation given that the average stress Yf= 2600psi.

Use the relation 1bar = 105Pa = 14.5psi

[10]

b. A series of cold rolling operations are used to reduce the thickness of a plate from 50mm
down to 25mm in a two-high reversing mill. Roll diameter is 700mm and coefficient of
friction between the rolls and work is 0.15. The specification is that the draft is to be
equal on each pass. Calculate (a) minimum number of passes required (b) draft for each
pass(c ) Is the rolling operation feasible? Justify your answer.
[10]
Question Five
A solid cylindrical work-piece made of stainless steel is 150mm in diameter and 100mm high. It
is forged by open-die forging at room temperature with flat dies to 50-percent reduction in
height.Assuming that the coefficient of friction is 0.2, calculate the forging force end of the
stroke.[10]
Question Six
A cylindrical part is warm upset forged in an open die. The initial diameter is 45 mm and the
initial height is 40 mm. The height after forging is 25 mm. The coefficient of friction at the diework interface is 0.20. The yield strength of the work material is 285 MPa, and its flow curve is
defined by a strength coefficient of 600 MPa and a strain-hardening exponent of 0.12. Determine
the force in the operation (a) just as the yield point is reached (yieldat strain = 0.002), (b) at a
height of 35 mm, (c) at a height of 30 mm, and (d) at a height of 25 mm.
[15]
Total Marks = 115=100%

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