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Tutorial 3 Bulk Deformation

This document contains 10 problems related to various metal forming processes including rolling, extrusion, forging, drawing, and heading. The problems involve calculating parameters such as number of passes, draft, forces, torques, pressures, strains, and reductions given information about the process, materials, and dimensions.

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Sawai Parihar
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69 views2 pages

Tutorial 3 Bulk Deformation

This document contains 10 problems related to various metal forming processes including rolling, extrusion, forging, drawing, and heading. The problems involve calculating parameters such as number of passes, draft, forces, torques, pressures, strains, and reductions given information about the process, materials, and dimensions.

Uploaded by

Sawai Parihar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING AND ARCHITECTURE


MBM UNIVERSITY JODHPUR

Subject: Manufacturing Technology ME 404 A

Tutorial # 3

Topic: Bulk Deformation

1. A series of cold rolling operations are to be used to reduce the thickness of a plate from
50 mm down to 25 mm in a reversing two-high mill. Roll diameter = 700 mm and
coefficient of friction between rolls and work = 0.15. The specification is that the draft
is to be equal on each pass. Determine (a) minimum number of passes required, and (b)
draft for each pass?
2. A plate that is 250 mm wide and 25 mm thick is to be reduced in a single pass in a two-
high rolling mill to a thickness of 20 mm. The roll has a radius = 500 mm, and its speed
= 30 m/min. The work material has a strength coefficient = 240 MPa and a strain
hardening exponent = 0.2. Determine (a) roll force, (b) roll torque, and (c) power
required to accomplish this operation.
3. A single-pass rolling operation reduces a 20 mm thick plate to 18 mm. The starting
plate is 200 mm wide. Roll radius = 250 mm and rotational speed = 12 rev/min. The
work material has a strength coefficient = 600 MPa and a strength coefficient = 0.22.
Determine (a) roll force, (b) roll torque, and (c) power required for this operation.
4. A cold heading operation is performed to produce the head on a steel nail. The strength
coefficient for this steel is 600 MPa, and the strain hardening exponent is 0.22.
Coefficient of friction at the die-work interface is 0.14. The wire stock out of which the
nail is made is 5.00 mm in diameter. The head is to have a diameter of 9.5 mm and a
thickness of 1.6 mm. The final length of the nail is 120 mm. (a) What length of stock
must project out of the die in order to provide sufficient volume of material for this
upsetting operation? (b) Compute the maximum force that the punch must apply to
form the head in this open-die operation.
5. A hot upset forging operation is performed in an open die. The initial size of the
workpart is: Do = 25 mm, and ho = 50 mm. The part is upset to a diameter = 50 mm.
The work metal at this elevated temperature yields at 85 MPa (n = 0). Coefficient of
friction at the die-work interface = 0.40. Determine (a) final height of the part, and (b)
maximum force in theoperation.
6. A 3.0-in-long cylindrical billet whose diameter = 1.5 in is reduced by indirect extrusion
to a diameter = 0.375 in. Die angle = 90°. In the Johnson equation, a = 0.8 and b = 1.5. In
the flow curve for the work metal, K = 75,000 lb/in2 and n = 0.25. Determine (a)
extrusion ratio, (b) true strain (homogeneous deformation), (c) extrusion strain, (d) ram
pressure, (e) ram force, and (f) power if the ram speed = 20 in/min.
7. A 2.0-in-long billet with diameter = 1.25 in is direct extruded to a diameter of 0.50 in.
The extrusion die angle = 90°. For the work metal, K = 45,000 lb/in2, and n = 0.20. In the
Johnson extrusion strain equation, a = 0.8 and b = 1.5. Determine (a) extrusion ratio, (b)
true strain (homogeneous deformation), (c) extrusion strain, and (d) ram pressure at L =
2.0, 1.5, 1.0, 0.5 and zero in. Use of a spreadsheet calculator is recommended for part (d).
8. A cylindrical billet that is 100 mm long and 50 mm in diameter is reduced by indirect
(backward) extrusion to a 20 mm diameter. The die angle is 90°. The Johnson equation
has a = 0.8 and b = 1.4, and the flow curve for the work metal has a strength coefficient
of 800 MPa and strain hardening exponent of 0.13. Determine (a) extrusion ratio, (b) true
strain (homogeneous deformation), (c) extrusion strain, (d) ram pressure, and (e) ram
force.
9. Bar stock of initial diameter = 90 mm is drawn with a draft = 15 mm. The draw die has
an entrance angle = 18°, and the coefficient of friction at the work-die interface = 0.08.
The metal behaves as a perfectly plastic material with yield stress = 105 MPa. Determine
(a) area reduction, (b) draw stress, draw force required for the operation, and (d) power to
perform the operation if exit velocity = 1.0 m/min.
10. A spool of wire has a starting diameter of 2.5 mm. It is drawn through a die with an
opening that is to 2.1 mm. The entrance angel of the die is 18° degrees. Coefficient of
friction at the work-die interface is 0.08. The work metal has a strength coefficient of 450
MPa and a strain hardening coefficient of 0.26. The drawing is performed at room
temperature. Determine (a) area reduction, (b) draw stress, and (c) draw force required
for the operation.

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