Alferid Hussin Shifa

11/30/2021
Prof. Makhlouf

Exam 2
QUESTION 1: Detail the features/properties/characteristics that you would investigate in order to tell
whether a given part is forged or cast.

- Non-destructive and destructive test methods, microscopy of the metal's structure, and

part inspection can all be used to distinguish between cast and forged parts. For instance,
tensile test can be used to assess how much a part will deform before it fails. Because
forged parts are more ductile than cast ones, they should bend more under tension than
cast parts. Also, we can use the relative grain size between parts using a microscope, to
distinguish between the two. Where with lower grain sizes being linked with forged
pieces. Deformation in a specific direction can be seen in forgings parts, while non-
directional deformation is more common in cast parts. Prior to particular post-production
treatments, inspection of the surfaces of cast and forged parts demonstrates that the cast
part has a less uniform surface structure. Finally, dye penetrant testing will reveal uneven
cracks in cast parts when compared to forged parts.
QUESTION 2:
a) Explain the difference between extrusion and drawing.
- Extrusion is a manufacturing process that generates in uniform cross-sectional
products. The material is shaped by forcing or squeezing material through a fixed dies
of the desired dimension to produce an evenly shaped product. Plastics are example
of a material that can be extruded extensively. Some of the products made by
extrusion are aluminum ladder, tubes, rods, trims, windows frames and architectural
shapes, and other products. Extrusion processes are generally divided into two
categories: hot extrusion and cold extrusion.
- Drawing is a manufacturing process that requires sharpening one end of a material to
the desired shape and thickness. When compared to extrusion, this method produces
items with a smaller cross-section area. By applying tensile force to the metal, it is
forced through fixed dies of a desired dimension by pulling to obtain smaller uniform
dimensioned. Cup-shaped parts made by sheet metal forming can be referred to the
drawing operation. Fibers, w ires, sheets, tubes with small cross sections, and other
products are commonly made using the Drawing technique. Drawing processes, like
extrusion, are divided into two categories: sheet metal drawing and wire and tube
drawing.

b) List and explain the types of defects that may occur in (i) extruded parts and (ii) drawn parts
i) Surface, pipe, and internal cracking are common faults in extrusion. Surface cracking occurs
when the extrusion temperature, friction, or speed is too high. The metal flow in extrusion
forces surface oxides and impurities to the core of the billet, resulting in the pipe defect.
Center cracking occurs when the extruded product develops cracks in the center.
ii) Similar defects to those seen in extrusion can occur during the drawing process too.
Due to the nature of the process, typical defects in a drawn rod or wire are center
cracking. Seams, which are longitudinal scratches or folds, are another common sort
of drawing imperfection. Seams may open up during subsequent forming operations,
such as rod or wire upsetting, thread rolling, or bending, posing major manufacturing
complications. Other surface defects, such as scratches and die markings, might occur
as a result of improper control factors setting, inadequate lubrication, or poor die
condition.
c) A round 70-30 brass billet is forward extruded at 675°C with a ram speed of 1 meter per minute.
The billet diameter is 125 mm, and the diameter of the extrusion is 50 mm. Knowing that for 70-
30 brass at the given extrusion temperature, k = 250 MPa, calculate:
i) The extrusion force in MN,

- Given data
70-30 brass billet: temp .=675° C , d 0=0.125 m, d e =0. 05 m, k =250 MPa
Find: extrusion force, F ex
 pi 2
d

( )
2
A 0 pi 2 4 o pi d
F ex = Ao∗k∗ln
( )
Ae
= d o∗k∗ln
4 pi 2
4
de
= d 2o∗k∗ln o2
4 de ( )
pi ( 0.125 m )2
4
(0.125 m)2∗250 MPa∗ln
(
( 0. 05 m )2)=5.622 MN

ii) The power required for the process in kW

6 m 1 m
- Given data, F ex =5.622∗10 N , v =1 =
min 60 sec
Find: power, P

P=F ex∗v=( 5.622∗106 ) N∗ ( 601 ) secm =93700 W =93.7 kW

QUESTION 3: An annealed 1100-O aluminum strip 9.0 inches wide and 1.0 inch thick is rolled to a
thickness of 0.8 inch in one pass. The roll radius is 8 inches and the rolls rotate at 100 rpm

a) Calculate the roll force in pounds (lbf)

- Given data: R = 8 in, N = 100 rmp, h o=1∈, H f =0.8 ∈¿ , w = 9 in

1100-O aluminum (figure 2.5) - Y ( aprox . yield stress) = 8000 psi, σ T =1 6 000 psi

- Find: the roll force, F, and the power, P

L= √ R( ho−H f )=√ 8(1−0.8)=1.265∈¿

Y +σ T 8 000+1 6 000 2 4 000

Y Avg = = = =1 2 000 psi
2 2 2

- F=Lw Y avg ,
F=1.265∈¿ 9∈¿1 2 000 psi=13 6 ,62 0 lb f
b) Calculate the power required for this operation in horse power (hp)

2 pi∗FL∗N
- P=
33,000
P=2 pi∗( 13 6 , 620 lb ) ¿ ¿
QUESTION 4:

a) List 4 characteristics of sheet metals that are important in sheet-forming operations.

- Sheet-metal forming is the process of converting bulk metal into small, thin sheets using
techniques such as spinning, bending, shearing, and stretching. Elongation, grain size,
Springback, and surface condition are critical characteristics for sheet metal forming.

b) Explain why each characteristic that you listed in (a) is important.

- The ability of a material to withstand necking or stretching during forming operations is defined
by its elongation. Because sheet forming involves stretching of the material, a high uniform
elongation is required for optimal formability. In addition to uniform elongation and necking,
total elongation of the specimen is an important component in sheet metal formability.
- When bending or stretching a sheet metal part, grain size can alter the appearance of the part
by making it look rougher. The rougher the grain, the harsher the appearance. The ductility and
strength of a material are also affected by grain size.
- Springback is what happens when a plastically deformed sheet rises when the pressure is
released due to elastic recovery. It is important to account for Springback because it
might distort the part and result in dimension discrepancies. Overbending and punch
bottoming are two ways for controlling Springback.
- The sheet's surface condition is crucial since it might alter the finished piece's look or cause
tears or wrinkles.

c) Explain (step-by-step) how the forming limit diagram of a material is constructed.

- When setting up forming processes for a certain type of metal, Form Limiting Diagrams (FLD) are
useful since they display the safe and failure boundaries. The higher the curve in the Form
Limiting Diagrams, the better is its ability to be formed. FLD is constructed experimentally by
drawing a diagram between two strains, one of which is a major strain in the direction of applied
stress and the other of which is a minor stress or latitude strain. To determine FLD, we first
create grid pattern of circles by applying strain analysis technique. Like as, a blank sheet is
marked with grid circles (2.5-5 mm). Following that, the blank is stretched over a punch until the
grid patterns deform, causing necking and tearing. The points were then marked on the grid.
The distorted circles are then measured in the failed region to determine the primary and minor
strain. After the stretching, the initial circle has transformed into an ellipse shape. Finally, join
the different points which are noted while stretching the sheet metal. Generally, there ten date
points considers for developed the FLD.

d) Given that titanium has an average normal anisotropy value Ravg = 5.0 and aluminum has an
average normal anisotropy value Ravg = 0.8; which one (Ti or Al) is easier to draw into a cup-
shaped part? Explain your logic or no credit.
 - R_avg has been shown to have a consistent relationship with the Limiting Drawing Ratio (LDR),
indicating that a high R_avg improves deep drawability. As a result of its high R avg value,
Titanium (Ti) will be easier to deep draw.

QUESTION 5: An engineering student is attempting to demonstrate some aspects of metal

forming by placing a copper penny between the platens of a 60,000 lb capacity press and
applying pressure. Assume that the coin has a 0.75 in. diameter and is 0.0625 in. thick; its yield
strength is 50,000 psi, and since no lubricant is applied, the friction factor is 1.00.
1+2 μR
force=pi∗R 2∗σ o
3 √3 T
a) Calculate the force required to induce plastic deformation.

Given data: P = 60,000 lb, d = 0.75 in, T = 0.0625 in, σ o = 50,000 psi, μ=1

force=pi∗¿ ¿
b) If this force is greater than the capacity of the press, calculate the pressure when the full-
capacity force is applied.
P
pmax = ,∧Total Surface Area , A=2∗pi∗r∗(r + t)
A
P 60,000 ib
pmax = = =58,205.24 psi
2 pi∗r∗(r +T ) 2 pi∗( 0.75 )( 0.75 +0.0625)
2 2
c) If the press surfaces are made from thick plates of a material with yield strength of 120,000 psi,
describe the results of the demonstration.
force=pi∗¿ ¿
- As this force is higher, nothing will happen to penny.