Rolling

1. De ne (a) roll gap, (b) neutral point, and (c) draft

2. List the defects commonly observed in at rolling.
3. Why is the surface nish of a rolled product better in cold rolling
than in hot rolling?
4. How is back tension generated?
5. What are the advantages of tandem rolling? Pack rolling?
6. Describe ring rolling. Is there a neutral plane in ring rolling?
7. How are seamless tubes produced?
8. Explain the types of de ections that rolls undergo.
9. What is forward slip? Why is it important?
10. Why may roller leveling be a necessary operation.
Problems
1. Given: An annealed copper strip 225 mm wide and 25 mm thick
is being rolled to a thickness of 20 mm in one pass. The roll
radius is 300 mm, and the rolls rotate at 100 rpm. Find:
Calculate the roll force and the power required in this operation.
2. In previous Example calculate the roll force and the power for
the case in which the workpiece material is 1100-0 aluminum
and the roll radius, R, is 500 mm.
3. Estimate the roll force, F, and the torque for an AISI 1020
carbon-steel strip that is 200 mm wide 12 mm thick, and rolled
to a thickness of 6 mm. The roll radius is 200 mm, and it rotates
at 200 rpm.
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 4. A rolling operation takes place under the conditions shown in
the accompanying gure. What is the position, Xn, of the neutral
point? Note that there are a front and back tension that have
not been speci ed. Additional data are as follows: Material is
5052-0 aluminum; hardened steel rolls; surface roughness of
the rolls = 0.025 um; rolling temperature = 210°C

5. A at-rolling operation is being carried out where h. = 6 mm, h f

= 5 mm, w. = 300 mm, R = 250 mm, u = 0.25, and the average
ow stress of the material is 275 MPa. Estimate the roll force
and the torque.
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 Forging process
1. What is the di erence between cold, warm, and hot forging?
2. Explain the di erence between open-die and impression-die
forging.
3. Explain the di erence between fullering, edging, and blocking.
4. What is ash? What is its function?
5. Why is the intermediate shape of a part important in forging
operations?
6. Describe the features of a typical forging die.
7. Explain what is meant by “load limited,” “energy limited,” and
“stroke limited” as these terms pertain to forging machines.
8. What are the advantages and disadvantages of isothermal
forging?
9. Why is hubbing an attractive alternative to producing simple
dies?
10. What is the di erence between piercing and punching?
Problems
1. Take two solid, cylindrical specimens of equal diameter, but
di erent heights, and compress them (frictionless) to the same
percent reduction in height. Show that the nal diameters will
be the same.
2. Calculate the room-temperature forging force for a solid,
cylindrical workpiece made of 5052-O aluminum that is 100
mm high and 125 mm in diameter and is to be reduced in
height by 30%. Let the coe cient of friction be 0.15.
3. calculate the forging force for A solid cylindrical workpiece is
150 mm in diameter and 100 mm in height. It is reduced in
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 height by 50%, at room temperature, in an open-die forging
operation with at dies. assuming that the material is1100-O
aluminum and that the coe cient of friction is 0.10.
4. Given: A solid cylindrical workpiece made of 304 stainless steel
is 150 mm in diameter and 100 mm in height. It is reduced in
height by 50%, at room temperature, in an open-die forging
operation with at dies. Assume that the coe cient of friction is
0.2. Find: What is the forging force at the end of the stroke?
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 Metal Extrusion and Drawing Processes
1. How does extrusion di er from rolling and forging?
2. Explain the di erence between extrusion and drawing.
3. What is a dead-metal zone?
4. De ne the terms (a) cladding, (b) dummy block, (c) shear dies,
(d) skull, and (e) canning.
5. Why is glass a good lubricant in hot extrusion?
6. What types of defects may occur in (a) extrusion and (b)
drawing?
7. Describe the di erence between direct and reverse extrusion.
8. It is possible to extrude straight gears; can helical gears also be
extruded? Explain.
9. What is impact extrusion?
10. What is the pipe defect in extrusion?
11. List the similarities and di erences between direct extrusion
and drawing.
12. The extrusion ratio, die geometry, extrusion speed, and billet
temperature all a ect the extrusion pressure. Explain why.
13. What is the function of a stripper plate in impact extrusion?
Problems
1. Given: A round billet made of 70–30 brass is extruded at a
temperature of 675◦C. The billet diameter is 125 mm, and the

diameter of the extrusion is 50 mm. Find: Calculate the

extrusion force required.
2. Estimate the force required in extruding 70–30 brass at 700◦C

if the billet diameter is 250 mm and the extrusion ratio is 25.

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3. Calculate the extrusion force for a round billet 300 mm in
diameter, made of stainless steel, and extruded at 1000◦C to a

diameter of 90 mm.
4. A planned extrusion operation involves steel at 1000◦C with

an initial diameter of 100 mm and a nal diameter of 25 mm.

Two presses, one with capacity of 20 MN and the other with a
capacity of 10 MN, are available for the operation. Is the
smaller press su cient for this operation? If not, what
recommendations would you make to allow the use of the
smaller press?
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