QUIZ MS204

Bulk Deformation Processes

Lucas Montogue

PROBLEM – PLAIN STRAIN COMPRESSION

▐ Problem 1 (Creese, 1999)
A square bar, 0.5 × 0.5 in. in cross-section and 5 in. long is to be flattened
into a section that is only 0.08 in. thick and will remain 5 in. in length. The press
velocity is 60 in./min and the coefficient of friction is 0.12. The strength coefficient
and strain-hardening exponent for cold working are 63,300 psi and 0.33,
respectively. For hot working at the pertinent temperature, the values are 12,700
psi and 0.06. True or false?

1.( ) The final width of the bar is greater than 3 in.

2.( ) The absolute value of the engineering strain is greater than 0.8.
3.( ) The absolute value of the true strain is greater than 2.0.
4.( ) The engineering strain rate is greater than 3 sec-1.
5.( ) The true strain rate is greater than 14 sec-1.
6.( ) The pressure multiplying factor is greater than 15.
7.( ) The flow stress for cold working is greater than 75,000 psi.
8.( ) The mean flow stress for cold working is greater than 60,000 psi.
9.( ) The flow stress for hot working is greater than 12,000 psi.
10.( ) The force needed for the hot working operation is greater than 1500 tons.

PROBLEMS – EXTRUSION
▐ Problem 2 (Kalpakjian & Schmid, 2010)
Calculate the extrusion force for a round billet 300 mm in diameter, made
of stainless steel, and extruded at 1000oC to a diameter of 100 mm. The extrusion
constant is 180 MPa.
A) 𝐹𝐹 = 9.51 MN
B) 𝐹𝐹 = 15.0 MN
C) 𝐹𝐹 = 21.5 MN
D) 𝐹𝐹 = 28.0 MN

▐ Problem 3 (Kalpakjian & Schmid, 2010)

A planned extrusion operation involves stainless steel at 1000oC with an
initial diameter of 100 mm and a final diameter of 50 mm. Two presses are
available for the operation: press 1 has a capacity of 20 MN and press 2 has a
capacity of 10 MN. Are the presses sufficient for this operation? The extrusion
constant is 320 MPa.
A) Both presses are suitable for the operation.
B) Press 1 is suitable for the operation, but press 2 is not.
C) Press 2 is suitable for the operation, but press 1 is not.
D) Neither press is suitable for the operation.

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▐ Problem 4 (Groover, 2013, w/ permission)
A cylindrical billet is 100 mm long and 50 mm in diameter is reduced by
indirect (backward) extrusion to a 20 mm diameter. The die angle is 90o. The
Johnson equation has 𝑎𝑎 = 0.8 and 𝑏𝑏 = 1.4. The ram speed is 50 cm/min. In the flow
curve for the work metal, the strength coefficient is 800 MPa and the strain
hardening exponent is 0.13. True or false?
1.( ) The extrusion ratio is greater than 6.0.
2.( ) The true strain is greater than 2.0.
3.( ) The extrusion strain is greater than 3.6.
4.( ) The ram pressure is greater than 2400 MPa.
5.( ) The ram force is greater than 6 MN.
6.( ) The power required to carry out the extrusion is greater than 38 kW.

▐ Problem 5 (Groover, 2013, w/ permission)

A 3.0-in.-long cylindrical billet whose diameter = 1.5 in. is reduced by
indirect extrusion to a diameter = 0.375 in. The die angle is 90o. In the Johnson
equation, 𝑎𝑎 = 0.8 and 𝑏𝑏 = 1.5. The ram speed is 20 in./min. In the flow curve for the
work metal, 𝐾𝐾 = 75,000 lb/in.² and 𝑛𝑛 = 0.25. True or false?
1.( ) The extrusion ratio is greater than 18.
2.( ) The true strain is greater than 2.4.
3.( ) The extrusion strain is greater than 5.5.
4.( ) The ram pressure is greater than 400 ksi.
5.( ) The ram force is greater than 650 kip.
6.( ) The power required to carry out the extrusion is greater than 30 hp.

PROBLEMS – WIRE DRAWING AND SHEET METAL

DRAWING
▐ Problem 6 (Groover, 2013, w/ permission)
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 angle of the die is 18 degrees. The
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 exponent of 0.26. The exit
velocity of the stock is 0.6 m/s. The drawing is performed at room temperature.
True or false?
1.( ) The area reduction is greater than 0.25.
2.( ) The draw stress is greater than 175 MPa.
3.( ) The draw force is greater than 500 N.
4.( ) The power required to carry out the operation is greater than 360 W.

▐ Problem 7 (Groover, 2013, w/ permission)

Red stock that has an initial diameter of 0.50 in. is drawn through a draw
die with an entrance angle of 13 degrees. The final diameter of the rod is 0.375 in.
The metal has a strength coefficient of 40,000 lb/in.² and a strain hardening
exponent of 0.20. The coefficient of friction at the work-die interface is 0.1. The exit
velocity of the stock is 2 ft/sec. True or false?
1.( ) The area reduction is greater than 0.5.
2.( ) The draw stress is greater than 27,200 psi.
3.( ) The draw force is greater than 3200 lb.
4.( ) The power required to carry out the operation is greater than 10 hp.

▐ Problem 8 (Groover, 2013, w/ permission)

A cup is to be drawn in a deep drawing operation. The height of the cup is
75 mm and its inside diameter = 100 mm. The sheet-metal thickness = 2 mm. If
the blank diameter = 225 mm, determine drawing ratio, reduction, and thickness-
to-diameter ratio. True or false?
1.( ) The drawing ratio is greater than 2.0.
2.( ) The reduction is greater than 50%.
3.( ) The thickness-to-diameter ratio is greater than 1%.
Repeat the calculations if the starting blank diameter = 175 mm.
4.( ) The drawing ratio is greater than 1.6.
5.( ) The reduction is greater than 45%..
6.( ) The thickness-to-diameter ratio is greater than 1.1%.

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 ▐ Problem 9 (Groover, 2013, w/ permission)
A cup-drawing operation is performed in which the inside diameter = 80
mm and the height = 50 mm. The stock thickness = 3.0 mm and the starting blank
diameter = 150 mm. Punch and die radii = 4 mm. Tensile strength = 400 MPa and
yield strength = 180 MPa for this sheet metal. True or false?
1.( ) The drawing ratio is greater than 1.8.
2.( ) The reduction is greater than 50%.
3.( ) The drawing force is greater than 320 kN.
4.( ) The blankholder force is greater than 120 kN.

▐ Problem 10 (Kalpakjian & Schmid, 2010, w/ permission)

For a metal, the normal anisotropy in the 0o, 45o, and 90o directions are
0.8, 1.7, and 1.8, respectively. True or false?
1.( ) The average normal anisotropy equals 1.4.
2.( ) The limiting drawing ratio is greater than 2.5.
3.( ) The metal will not develop ears when deep drawn.

PROBLEMS – ROLLING

■ Problem 11.1 (Groover, 2013, w/ permission)

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. The roll diameter
= 700 mm and the coefficient of friction between rolls and work = 0.15. The
specification is that the draft is to be equal on each pass. Determine the minimum
number of passes required.
A) Minimum number of passes = 3
B) Minimum number of passes = 4
C) Minimum number of passes = 5
D) Minimum number of passes = 6

■ Problem 11.2
Determine the draft for each pass.
A) 𝑑𝑑 = 4.10 mm
B) 𝑑𝑑 = 4.95 mm
C) 𝑑𝑑 = 6.25 mm
D) 𝑑𝑑 = 7.70 mm

▐ Problem 12 (Groover, 2013, w/ permission)

A 42-mm-thick plate made of low carbon steel is to be reduced to 34.0
mm in one pass in a rolling operation. As the thickness is reduced, the plate widens
by 4%. The yield strength of the steel plate is 174 MPa and the tensile strength is
290 MPa. The entrance speed of the plate is 15.0 m/min. The roll radius is 325 mm
and the rotational speed is 49.0 rev/min. True or false?
1.( ) The coefficient of friction that makes the operation possible is greater than 0.14.
2.( ) The exit velocity of the plate is greater than 19 m/min.
3.( ) The forward slip is greater than 0.097.

▐ Problem 13 (Groover, 2013, w/ permission)

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. True or false?
1.( ) The roll force is greater than 2.0 MN.
2.( ) The roll torque is greater than 40 kN∙m.
3.( ) The power required to carry out the operation is greater than 100 kW.
Repeat the calculations if the roll radius = 250 mm.
4.( ) The roll force is greater than 1.2 MN.
5.( ) The roll torque is greater than 25 kN∙m.
6.( ) The power required to carry out the operation is greater than 86 kW.

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▐ Problem 14 (Groover, 2013, w/ permission)
A hot rolling mill has rolls of diameter = 24 in. It can exert a maximum force
= 400,000 lb. The mill has maximum horsepower = 100 hp. It is desired to reduce a
1.5-in. thick plate by the maximum possible draft in one pass. The starting plate is
10 in. wide. In the heated condition, the work material has a strength coefficient =
20,000 lb/ft2 and a strain hardening exponent = zero. True or false?
1.( ) The maximum possible draft is greater than 0.28 in.
2.( ) The true strain is greater than 0.29.
3.( ) The maximum speed of the rolls is greater than 45 ft/min.

PROBLEMS – FORGING
▐ Problem 15 (Groover, 2013, w/ permission)
A hot upset forging operation is performed in an open die. The workpart has
initial diameter = 25 mm and initial height = 50 mm. The work metal at this
elevated temperature yields at 85 MPa (strain-hardening exponent = 0). The
coefficient of friction at the die-work interface = 0.40. Determine the final height of
the part and the forging force.
A) ℎ = 12.5 mm and 𝐹𝐹 = 144 kN
B) ℎ = 12.5 mm and 𝐹𝐹 = 273 kN
C) ℎ = 23.5 mm and 𝐹𝐹 = 144 kN
D) ℎ = 23.5 mm and 𝐹𝐹 = 273 kN

▐ Problem 16 (Groover, 2013, w/ permission)

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 die-work 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 just as the yield point is reached (strain at yield = 0.002), at a height of
35 mm, a height of 30 mm, a height of 25 mm, and a height of 20 mm.

▐ Problem 17 (Groover, 2013, w/ permission)

A cylindrical workpart has a diameter = 2.5 in. and a height = 4.0 in. It is
upset forged to a height = 2.75 in. The coefficient of friction of the die-work
interface = 0.10. The work material has a flow curve with strength coefficient =
25,000 lb/in.² and strain hardening exponent = 0.22. Prepare a plot of force vs.
work height.

ADDITIONAL INFORMATION

Figure 1 Relationship between average normal anisotropy

and limiting drawing ratio for various sheet metals.

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Equations
1  Pressure-multiplying factor for plain strain compression (𝜇𝜇𝜇𝜇⁄ℎ ≤ 1)

µL
Q= 1+
2h
where 𝜇𝜇 is the coefficient of friction, 𝐿𝐿 is length (or width), and ℎ is height.

2  Pressure-multiplying factor for plain strain compression (𝜇𝜇𝜇𝜇⁄ℎ > 1)

L
Q= 1+
4h
where 𝜇𝜇 is the coefficient of friction, 𝐿𝐿 is length (or width), and ℎ is height.

3  Extrusion force

A 
F = Ao k ln  o 
A
 f 
where 𝐴𝐴𝑜𝑜 is initial area, 𝐴𝐴𝑓𝑓 is final area, and 𝑘𝑘 is the extrusion constant.

4  Johnson equation for extrusion strain

ε x= a + b ln rx
where 𝑟𝑟𝑥𝑥 is extrusion ratio and 𝑎𝑎 and 𝑏𝑏 are coefficients.

5  Schey equation for wire and bar drawing

 µ   Ao 
σ d σ f 1 +
=  φ ln  
 tan α   Af 
where 𝜎𝜎�𝑓𝑓 is average flow stress, 𝜇𝜇 is coefficient of friction, 𝛼𝛼 is die angle (half-angle),
𝐴𝐴𝑜𝑜 is initial area, and 𝐴𝐴𝑓𝑓 is final area; 𝜙𝜙 is a factor that accounts for inhomogeneous
deformation, which, in the case of a round cross-section, is given by

D
φ 0.88 + 0.12
=
Lc

where 𝐷𝐷 is average diameter of work during drawing and 𝐿𝐿𝑐𝑐 is the contact length of
the work with the draw die, which can be estimated as

Do − D f
Lc =
2sin α
6  Drawing force (sheet metal working)

D 
=F π D p tσ T  b − 0.7 
 
 Dp 
where 𝐷𝐷𝑏𝑏 is starting blank diameter, 𝐷𝐷𝑝𝑝 is starting punch diameter, 𝑡𝑡 is thickness,
and 𝜎𝜎𝑇𝑇 is tensile strength.

7 Blankholder force (sheet metal working)

Fb 0.015σ Y π  Db2 − ( D p + 2.2t + 2 Rd ) 

2
=
 
where 𝜎𝜎𝑌𝑌 is yield strength, 𝐷𝐷𝑏𝑏 is starting blank diameter, 𝐷𝐷𝑝𝑝 is starting punch
diameter, 𝑡𝑡 is thickness, and 𝑅𝑅𝑑𝑑 is die corner radius.

8  Average normal anisotropy

R0 + 2 R45 + R90
Ravg =
4
where 𝑅𝑅n is the normal anisotropy when 𝑛𝑛 is the angle with respect to the rolling
direction of the sheet.

9  Average normal anisotropy

R − 2 R45 + R90
∆R = 0
2

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where 𝑅𝑅n is the normal anisotropy when 𝑛𝑛 is the angle with respect to the rolling
direction of the sheet.

10  Forging shape factor

0.4 µ D
K f = 1+
h
where 𝜇𝜇 is friction factor, 𝐷𝐷 is diameter, and ℎ is height.

SOLUTIONS
P.1 ■ Solution
1. True. The volume of the material is conserved, so the final width can be
determined as

0.5 × 0.5 × 5 = w × 0.08 × 5 → w = 3.13 in.

2. True. The engineering strain is given by

0.08 − 0.5
ε= = −0.84
0.5
3. False. The true strain is given by

 0.08 
ε = ln   = −1.83
 0.5 
4. False. The engineering strain rate is

60 in./min ×1 min 60 sec

=ε = 2 s −1
0.5
5. False. The true strain rate is

60 in./min ×1min/60 sec

ε = = 12.5 s −1
0.08
6. True. If 𝜇𝜇𝜇𝜇/ℎ ≤ 1, the pressure multiplying factor is computed with
equation 1, namely

µL
Q= 1+
2h
If, on the other hand, 𝜇𝜇𝜇𝜇/ℎ > 1, the expression to use is equation 2,

L
Q= 1+
4h
In the case at hand,

µ L 0.12 × 5
= = 12
h 0.05
which implies that the relation to use is equation 2. Accordingly,

L 3.13
1
Q =+ 1
=+ =16.7
4h 4 × 0.05
7. True. If cold working is performed, the values of 𝐾𝐾 and 𝑛𝑛 in the flow curve
are 63,300 psi and 0.33, respectively. Therefore,

σf =Kε n =63,300 ×1.830.33 =77,300 psi

Although the strain was in fact −1.83, the absolute value is entered in the
equation. The minus sign implies compression instead of tension, but the formula is
for either.

8. False. The mean flow stress for cold working is

63,300 ×1.830.33
=σ f = 58,100 psi
1 + 0.33
9. True. If hot working is done instead, the values of 𝐾𝐾 and 𝑛𝑛 in the flow
curve are 12,700 psi and 0.06, respectively. Thus,

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 σf =Kε n =
12, 700 ×1.830.06 =13, 200 psi

10. True. If hot working is used, and the flow stress and pressure-
multiplying factor have been computed, the surface area is the only additional
information needed. The surface area is 𝐴𝐴𝑓𝑓 = 5 × 3.13 = 15.7 in.². Accordingly,

F = Qσ f Af = 16.7 ×13, 200 ×15.7 = 3.46 ×106 lb

1 ton
∴ F= 3.46 ×106 lb × = 1730 tons
2000 lb

P.2 ■ Solution
The extrusion force required is given by equation 3,

A 
F = Ao k ln  o 
A
 f 
where 𝐴𝐴𝑜𝑜 = 𝜋𝜋 × 0.3²/4 = 0.0707 m² is the initial cross-sectional area, 𝐴𝐴𝑓𝑓 = 𝜋𝜋 ×
0.1²/4 = 0.00785 m² is the final cross-sectional area, and 𝑘𝑘 = 180 MPa is the
extrusion constant. Thus,

A   0.0707 
Ao k ln  o
F= 0.0707 ×180 ln 
 = =28.0 MN
A  0.00785 
 f 
♦ The correct answer is D.

P.3 ■ Solution
The initial cross-sectional area is 𝐴𝐴𝑜𝑜 = 𝜋𝜋 × 0.1²/4 = 0.00785 m² and the
final cross-sectional area is 𝐴𝐴𝑓𝑓 = 𝜋𝜋 × 0.052/4 = 4.91×10-4 m². The extrusion force is
then

A   0.00785 
Ao k ln  o  =
F= 0.00785 × 320 ln  =6.96 MN
A   0.00196 
 f 
Accordingly, both the smaller press and the larger press can accommodate
this extrusion operation. The smaller press would probably not be used because it is
so close to the required force. Reducing friction or increasing the extrusion
temperature may reduce the required extrusion force.

♦ The correct answer is A.

P.4 ■ Solution
1. True. The extrusion ratio is the ratio of initial cross-sectional area to final
cross-sectional area; that is,

Ao Do2 502
rx = =
= = 6.25
Af D 2f 202

2. False. The true strain follows as

ε ln=
= rx ln 6.25
= 1.83

3. False. The extrusion strain follows from the Johnson equation (equation 4)

εx =
a + b ln rx =+
0.8 1.4 ln 6.25 =
3.37

4. True. Before computing the ram pressure, we require the flow stress 𝜎𝜎�𝑓𝑓 ;
that is,

800 ×1.830.13
=σf = 766 MPa
1 + 0.13
Therefore,

p = ε xσ f = 3.37 × 766 = 2580 MPa

5. False. The initial cross-sectional area is 𝐴𝐴𝑜𝑜 = 𝜋𝜋 × 50²/4 = 1960 mm².

The corresponding ram force is

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 F = pAo =2580 ×1960 = 5.06 MN

6. True. The ram speed is converted as

m 1 min
V = 0.5 × = 0.00833 m/s
min 60 sec
so that

P = FV = ( 5.06 ×106 ) × 0.00833 = 42.1 kW

P.5 ■ Solution
1. False. The extrusion ratio is the ratio of initial cross-sectional area to
final cross-sectional area; that is,

Ao Do2 1.52
rx
= = = = 16
Af D 2f 0.3752

2. True. The true strain is given by

ε ln=
= rx ln16
= 2.77

3. False. The extrusion strain follows from the Johnson equation,

εx =
a + b ln rx =+
0.8 1.5ln16 =
4.96

4. False. Before computing the ram pressure, we require the flow stress 𝜎𝜎�𝑓𝑓 ;
that is,

75, 000 × 2.77 0.25

=σf = 77, 400 psi
1 + 0.25
Accordingly,

ε xσ f =
p= 4.96 × 77, 400 =384 ksi

5. True. The initial cross-sectional area is 𝐴𝐴𝑜𝑜 = 𝜋𝜋 × 1.52/4 = 1.77 in.² The
corresponding ram force is

F = pAo =384 ×1.77 = 680 kip

6. True. The power associated with the extrusion process is

P = FV = 680, 000 × 20 = 1.36 ×107 in.-lb/min

1 hp
∴ P= 1.36 ×107 in.-lb/min × = 34.3 hp
396, 000 in.-lb/min

P.6 ■ Solution
1.True. The initial area is 𝐴𝐴𝑜𝑜 = 𝜋𝜋 × 2.5²/4 = 4.91 mm² and the final area is
𝐴𝐴𝑓𝑓 = 𝜋𝜋 × 2.1²/4 = 3.46 mm². The area reduction is then

Ao − Af 4.91 − 3.46
=r = = 0.295
Ao 4.91

2.False. The true strain is

 Ao  4.91
=ε ln=
  ln= 0.350
 Af  3.46

and the corresponding flow stress is

450 × 0.3500.26
=σ f = 272 MPa
1 + 0.26
The homogeneous deformation factor 𝜙𝜙 is given by

D
φ 0.88 + 0.12
=
Lc

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 Here, 𝐷𝐷 is the average diameter of work during drawing,

Do + D f 2.1 + 2.5
=D = = 2.3 mm
2 2
and 𝐿𝐿𝑐𝑐 is the contact length of the work with the draw die, calculated as

Do − D f 2.5 − 2.1
=Lc = = 0.647 mm
2sin α 2sin18o
where we have used the die angle 𝛼𝛼 = 18o. Substituting in the formula for 𝜙𝜙 brings
to

2.3
φ = 0.88 + 0.12 × = 1.31
0.647
We can now compute the drawing stress using equation 5,

 µ   Ao   0.08   4.91 
σ d = σ f 1 +  φ ln   = 272 × 1 +  ×1.31× ln   = 155 MPa
 tan α   A  tan18º  3.46  
 f 
3.True. The draw force is the product of the final cross-sectional area and
draw stress; that is,

Fd =σ d Af =155 × 3.46 = 536 N

4.False. The power required to carry out the operation is

P = FdV = 536 × 0.6 = 322 W

P.7 ■ Solution
1.False. The initial area is 𝐴𝐴𝑜𝑜 = 𝜋𝜋 × 0.5²/4 = 0.196 in.² and the final area is
𝐴𝐴𝑓𝑓 = 𝜋𝜋 × 0.375²/4 = 0.110 in.². The area reduction is, accordingly,
Ao − Af 0.196 − 0.110
=r = = 0.439
Ao 0.196
2.False. The true strain is

A  0.196
=ε ln=
 o  ln= 0.578
 Af  0.110

and the corresponding flow stress is

40, 000 × 0.5780.20

=σf = 29,900 psi
1 + 0.20
The homogeneous deformation factor 𝜙𝜙 is given by

D
φ 0.88 + 0.12
=
Lc

Here, 𝐷𝐷 is the average diameter of work during drawing,

Do + D f 0.5 + 0.375
=D = = 0.438 in.
2 2
and 𝐿𝐿𝑐𝑐 is the contact length of the work with the draw die, namely

Do − D f 0.5 − 0.375
=Lc = = 0.278 in.
2sin α 2sin13o
where we have used the die angle 𝛼𝛼 = 13o. Substituting in the formula for 𝜙𝜙 gives

0.438
φ = 0.88 + 0.12 × = 1.07
0.278
The draw stress is determined to be

 µ   Ao   0.1   0.196 
σ=
d σ f 1 +  φ ln  =  29,900 × 1 +  × 1.07 × ln  = 26,500 psi
 tan α  A f  tan13º
  0.110  

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 3.False. The draw force is the product of the final cross-sectional area and
draw stress,

Fd = σ d Af = 26,500 × 0.110 = 2920 lb

4.True. The exit velocity is converted as

ft in. sec
V= 2 ×12 × 60 = 1440 in./min
sec ft min
The power required to carry out the operation is

P = FdV = 2920 ×1440 = 4.20 ×106 in.-lb/min

1 hp
∴ P= 4.20 ×106 in.-lb/min × = 10.6 hp
396, 000 in.-lb/min
P.8 ■ Solution
1.True. The drawing ratio is the ratio of blank diameter to inside diameter,
namely

Db 225
DR
= = = 2.25
D p 100
2.True. The reduction is given by

Db − D p 225 − 100
=r = = 55.6%
Db 225

3.False. The thickness-to-diameter ratio is

t 2
= = 0.00889
= 0.89%
Db 225

Note
It is important to appreciate that these data may not indicate a feasible
drawing operation. Approximate upper limits are 2.0 for the drawing ratio and
0.5 for the reduction; the thickness-to-diameter ratio should be greater than 1%.
Since the values at hand satisfy none of these requirements, we surmise that this
system does not represent a viable drawing operation.

4.True. The drawing ratio is now

Db 175
DR
= = = 1.75
D p 100

5.False. The reduction, in turn, now becomes

Db − D p 175 − 100
=r = = 42.9%
Db 175

6.True. The thickness-to-diameter ratio is

t 2
= = 1.14%
Db 175

In this case, 𝐷𝐷𝐷𝐷 < 2.0, 𝑟𝑟 < 50%, and 𝑡𝑡⁄𝐷𝐷𝑏𝑏 > 1%. However, Groover observes
that the operation is not feasible because the 175 mm diameter blank size does
not provide sufficient metal to draw a 75 mm cup height. The actual cup height
possible with a 175 mm diameter blank can be determined by comparing surface
areas (one side only for convenience) between the cup and the starting blank. The
blank area = 𝜋𝜋 × 175²/4 = 24,100 mm². To compute the cup surface area, let us
divide the cup into two sections: (1) walls and (2) base, assuming the corner
radius on the punch has a negligible effect in our calculations and there is no
earing of the cup. The cup area = 𝜋𝜋𝐷𝐷𝑝𝑝 ℎ + 𝜋𝜋𝐷𝐷𝑝𝑝2/4 = 𝜋𝜋 × 100ℎ + 𝜋𝜋 × 100²/4 =
314ℎ + 7850. Setting the surface area of cup = surface area of the blank, it
follows that

Acup = Ablank → 314h + 7850 = 24,100

∴ 314h =
16,300
∴h =51.9 mm
This is less than the specified 75 mm height.

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© 2020 Montogue Quiz
P.9 ■ Solution
1.True. The drawing ratio is

Db 150
DR
= = = 1.88
D p 80

2.False. The reduction is

Db − D p 150 − 80
=r = = 46.7%
Db 150

3.True. The drawing force is given by equation 6,

D 
F= π 0.08 × 0.003 × ( 400 ×106 ) × (1.88 − 0.7 ) =
π D p tσ T  b − 0.7  =× 356 kN
D 
 p 
4.False. The blankholder force is given by equation 7,

Fb 0.015πσ Y  Db2 − ( D p + 2.2t + 2 Rd ) 

2
=
 

Fb 0.015π ×180 × 1502 − ( 80 + 2.2 × 3 + 2 × 4=

)
2
∴
=  115 kN
 

P.10 ■ Solution
1. False. The average normal anisotropy is given by equation 8,

R0 + 2 R45 + R90 0.8 + 2 ×1.7 + 1.8

=Ravg = = 1.5
4 4
2. True. The limiting drawing ratio (LDR) is plotted as a function of average
normal anisotropy/strain ratio in Figure 1. Entering 𝑅𝑅avg = 1.5 in this chart, we read
a LDR of about 2.8.

3. False. The planar anisotropy is given by equation 9,

R − 2 R45 + R90 0.8 − 2 ×1.7 + 1.8

∆R = 0 = =−0.4
2 2
If Δ𝑅𝑅 = 0, no ears would form. In the case at hand, Δ𝑅𝑅 ≠ 0, hence we cannot
conclude that ears will not form in the metal.

P.11 ■ Solution
Part 1: The maximum draft is

d max = µ 2 R = 0.152 × 350 = 7.88 mm

The minimum number of passes follows as

to − t f 50 − 25
Min. number of passes
= = = 3.17
=  4
d max 7.88

♦ The correct answer is B.

Part 2: The draft per pass is given by the ratio

50 − 25
=d = 6.25 mm
4
♦ The correct answer is C.

P.12 ■ Solution
1.True. The maximum draft is given by 𝑑𝑑max = 𝜇𝜇2 𝑅𝑅. We know that 𝑑𝑑 = 42 –
34 = 8 mm and 𝑅𝑅 = 325 mm. Accordingly,
12
d 
d max= µ R → µ=  max 
2

 R 
12
 8 
∴µ  =
=  0.157
 325 

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© 2020 Montogue Quiz
 2.False. From conservation of volume, we can write

to wo vo = t f w f v f

Since the plate widens by 4%, we have 𝑤𝑤𝑓𝑓 = 1.04𝑤𝑤𝑜𝑜 . Substituting this and
other data brings to

to wo vo
to wo=
vo t f w f v f → =
vf
t f wf
42 × w ×15.0
∴v f = o
34 ×1.04 wo

17.8 m min
∴ vf =

3.False. The roll speed is given by

vr =π r 2 N =π × 0.3252 × 49 =16.3 m min

The forward slip follows as

v f − vr 17.8 − 16.3
=s = = 0.0920
vr 16.3

P.13 ■ Solution
1.False. The contact length is

L= R ( t o − t f )= 500 × ( 25 − 20 )= 50 mm

The true strain is

 25 
=ε ln=
  0.223
 20 
and the average flow stress follows as

240 × 0.2230.2
=σf = 148 MPa
1 + 0.2
The roll force is determined next,

F =σ f wL =148 × 0.25 × 0.05 = 1.85 MN

2.True. The roll torque is

T =0.5 FL =0.5 ×1850 × 0.05 =46.3 kN ⋅ m

3.False. The rotational speed is converted as 𝑁𝑁 = 30 ÷ (2𝜋𝜋 × 0.5) ÷ 60 =

0.159 rev/s. It remains to compute the required power,

P =2π NFL =2π × 0.159 × (1.85 ×106 ) × 0.05 =92.4 kW

4.True. The draft continues to be 5 mm, but the contact length is now
shifted to

L= R ( to − t f )= 250 × ( 25 − 20 )= 35.4 mm

The true strain continues to be 0.223, which implies that the flow stress
still equals 148 MPa. The roll force is

F =σ f wL =148 × 0.25 × 0.0354 = 1.31 MN

5.False. The roll torque is

T =0.5 FL =0.5 ×1310 × 0.0354 =23.2 kN ⋅ m

6.True. The rotational speed is converted as 𝑁𝑁 = 30 ÷ (2𝜋𝜋 × 0.25) ÷ 60 =

0.318 rev/s. Lastly, the required power is determined to be

F =2π NFL =2π × 0.318 × (1.31×106 ) × 0.0354 =92.7 kW

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© 2020 Montogue Quiz
P.14 ■ Solution
1.True. The contact length is approximated as

L= R ( to − t f =
) 12d
 
=d

The flow stress is calculated as

20, 000 × ε 0
=σf = 20, 000 psi
0 + 1.0
The limiting force of the rolling mill is 400,000 lb. Accordingly,

= 20, 000 ×10 × (12d )

0.5
F σ f wL → 400, 000
=

200, 000 (12d )

0.5
∴ 400, 000 =

(12d )
0.5
∴2 =

0.333 in.
∴d=

2.False. Before computing the true strain, we require the final thickness 𝑡𝑡𝑓𝑓 .
Given the draft 𝑑𝑑 = 0.333 in., we write

d = to − t f → t f = to − d
∴ t f = 1.5 − 0.333
1.17 in.
∴t f =

Thus, the true strain is

 to   1.5 
=ε ln=
  ln =  0.248
 tf   1.17 

3.True. The maximum possible power is 𝑃𝑃 = 100 hp × 396,000 (in-

lb/min)/hp = 3.96×107 (in-lb/min). The contact length is 𝐿𝐿 = (12×0.333)0.5 = 2.0 in.
The rotational speed that corresponds to maximum power is

P
P 2π NFL →=
= N
2π FL
3.96 ×107
=∴N = 7.88 rev min
2π × 400, 000 × 2.0
Lastly, the maximum speed of the rolls is

vr =2π RN =2π × (12 12 ) × 7.88 =49.5 ft/min

P.15 ■ Solution
The volume of the workpart is 𝑉𝑉 = 𝜋𝜋 × 25² × 50/4 = 24,500 mm³ and the
final area is 𝐴𝐴𝑓𝑓 = 𝜋𝜋 × 50²/4 = 1960 mm². The final height of the part is then

V
V= Af h → h=
Af
24,500
∴h
= = 12.5 mm
1960
The strain associated with the operation is

 50 
=ε ln=
  1.39
 12.5 
The force is maximum at the largest area value 𝐴𝐴𝑓𝑓 = 1960 mm², which
corresponds to a diameter 𝐷𝐷 = 50 mm. Appealing to equation 10, the forging shape
factor is calculated as

0.4 µ D 0.4 × 0.4 × 50

1+
Kf = 1+
= 1.64
=
h 12.5

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© 2020 Montogue Quiz
 Lastly, the forging force is

F = K f σ f A= 1.64 × 85 ×1960= 273 kN

♦ The correct answer is B.

P.16 ■ Solution
The initial volume of the part is

V=π D 2 L 4 =π × 452 × 40 4 =63, 600 mm3

The flow stress at yield is

σ f =×
600 0.0020.12 =
285 MPa

The height of the part at yield is

h = 40 − 40 × 0.002 = 39.92 mm
and the corresponding area is

V
V = Ah → A =
h
63, 600
∴A
= = 1590 mm 2
39.92
The forging shape factor is determined next,

0.4 µ D 0.4 × 0.20 × 45

1+
Kf = 1+
= 1.09
=
h 39.92
It remains to compute the forging force,

F = K f σ f A = 1.09 × 285 ×1560 = 485 kN

The forces for other deformation values are tabulated below.

h (mm) Strain σf (MPa) A (mm²) D (mm) Kf F (kN)

35 0.134 471 1817 48.1 1.11 950
30 0.288 517 2120 52.0 1.14 1247
25 0.470 548 2544 56.9 1.18 1648
20 0.693 574 3180 63.6 1.25 2291

A plot of force (red column) vs. work height (blue column) is shown in
continuation.

P.17 ■ Solution
The volume of the cylinder is 𝑉𝑉 = 𝜋𝜋 × 2.5² × 4.0/4 = 19.6 in.³ At ℎ = 4.0 in.,
we assume yielding has just occurred and the height has not changed significantly.
As usual, we take the yield strain to be 𝜀𝜀 = 0.002. The flow stress is

σ f =25, 000 × 0.0020.22 =6370 psi

The height for this strain is

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© 2020 Montogue Quiz
 h = 4.0 − 0.002 × 4.0 = 3.992 in.
and the corresponding area is

V
V = Ah → A =
h
19.6
A
∴= = 4.91 in.²
3.992
The forging shape factor is

0.4 µ D 0.4 × 0.10 × 2.5

1+
Kf = 1+
= 1.03
=
h 4.0
Lastly, the forging force is

F = K f σ f A =1.03 × 6370 × 4.91 = 32, 200 lb

Forging forces for other values of final height are tabulated below.

h (in) Strain σf (psi) A (in.²) D (in.) Kf F (lb)

4 0.002 6370 4.91 2.50 1.03 32060
3.75 0.065 13680 5.23 2.58 1.03 73471
3.5 0.134 16053 5.60 2.7 1.03 92643
3.25 0.208 17691 6.03 2.8 1.03 110329
3 0.288 19006 6.53 2.9 1.04 128952
2.75 0.375 20144 7.13 3.0 1.04 149865

The load stroke curve is a plot of force (red column) versus height (blue
column), as shown in continuation.

REFERENCES
• CREESE, R. (1999). Introduction to Manufacturing Processes and
Materials. New York: Marcel Dekker.
• GROOVER, M. (2013). Fundamentals of Modern Manufacturing. 5th
edition. Hoboken: John Wiley and Sons.
• KALPAKJIAN, S. and SCHMID, S. (2010). Manufacturing Engineering and
Technology. 6th edition. Upper Saddle River: Pearson.

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© 2020 Montogue Quiz