Model Answer

Metal forming 2022

QUESTION 1:

𝑃 Δ𝑙
𝜎𝑒 = 𝑒=
𝐴𝑜 𝑙𝑜

𝐴𝑜 𝑙𝑜 = 𝐴𝑙
𝑙 𝑙𝑜 + Δ𝑙 𝐴𝑜
= =1+𝑒 =
𝑙𝑜 𝑙𝑜 𝐴

𝜖𝑡

𝑑𝑙
𝑑𝜖𝑡 =
𝑙𝑜
𝜖𝑖 𝑙𝑖
𝑑𝑙 𝑙𝑖
𝜖𝑡 = ∫ 𝑑𝜖𝑡 = ∫ = ln ( ) = ln(1 + 𝑒)
0 𝑙𝑜 𝑙𝑜 𝑙𝑜

𝑃
𝜎𝑡 =
𝐴
 𝑃 𝑃 (1 + 𝑒)
𝜎𝑡 = = = 𝜎𝑒 (1 + 𝑒)
𝐴 𝐴𝑜

• 𝜖𝑢

𝐴𝑜
𝜖𝑢 = ln ( )
𝐴𝑢

𝜎𝑢𝑡 = 𝑈𝑇𝑆 𝑒 𝜖𝑢

𝐴𝑜
𝜖𝑓 = ln ( )
𝐴𝑓
 •

𝐴𝑢
𝜖𝑛 = ln ( )
𝐴𝑓

QUESTION 2:

𝜎𝑡 = 𝐾𝜖 𝑛

𝑒 = 0.4

𝑛 = 𝜖 = ln(1 + 𝑒) = ln(1.4) = 0.336

𝜖1 = 𝜖𝑢𝑡𝑠 = 0.336 𝜎1 = 12000 𝐼𝑏𝑠

𝜖2 = ln(1 + 𝑒) = ln(1 + 0.2) = 0.182

𝜎2

𝜎2 𝐾𝜖2𝑛 𝜖2 𝑛 𝜖2 0.336
= =( ) = ( )
𝜎1 𝐾 𝜖1𝑛 𝜖1 𝜖1

𝜎2 0.183 0.336
= ( ) = 0.814
1200 0.336
𝜎2 = 1200 × 0.814 = 976.60 𝐼𝑏𝑠

𝐴𝑜 − 𝐴 𝐴 𝐴
𝑟= =1− =1−
𝐴𝑜 𝐴𝑜 exp(𝜖)

1
exp(𝜖) =
1−𝑟
1 1
𝜖 = ln ( ) 𝑟 = 0.5 𝜖 = ln ( ) = 0.693
1−𝑟 1−0.5

𝜎 = 700 𝜖 0.2 = 700 × 0.6930.2 = 650.50

𝑟 = (𝑥 + 0.15)
525 = 700 𝜖 0.2

525
ln (
𝜖 = exp ( 700)) = 0.237
0.2

1
ln ( ) = ϵ = 0.237
1−𝑟
1
= exp(0.237) = 1.268
1−𝑟
1 − 𝑟 = 0.7887

𝑟 = 0.211 = 𝑥 + 0.15 𝑥 = 0.061

QUESTION 3:

cos 𝜃 − sin 𝜃 0
𝑅𝑧 (𝜃) = [ sin 𝜃 cos 𝜃 0]
0 0 1
1 1
− 0
cos 45° − sin 45° 0 √2 √2
𝑅𝑧 (45°) = [ sin 45° cos 45° 0] = 1 1
0 0 1 0
√2 √2
[0 0 1]

4 2 3
𝝈 = [ 2 6 1]
3 1 5
 7 1 2.828
′
𝝈 = 𝑅𝑧𝑇 (45°)𝝈𝑅𝑧 (45°) =[ 1 3 −1.414]
2.828 −1.414 5

𝐼1 = 𝜎𝑥 + 𝜎𝑦 + 𝜎𝑧 = 15 ksi
2 2 2
𝐼2 = 𝜎𝑥 𝜎𝑦 + 𝜎𝑥 𝜎𝑧 + 𝜎𝑦 𝜎𝑧 − 𝜏𝑥𝑦 − 𝜏𝑥𝑧 − 𝜏𝑦𝑧 = 60 (ksi2 )
2 2 2
𝐼3 = 𝜎𝑥 𝜎𝑦 𝜎𝑧 + 2 𝜏𝑥𝑦 𝜏𝑥𝑧 𝜏𝑧𝑦 − 𝜎𝑥 𝜏𝑦𝑧 − 𝜎𝑦 𝜏𝑥𝑧 − 𝜎𝑧 𝜏𝑥𝑦 = 54 ksi3

𝜎 3 − 15 𝜎 2 + 60 𝜎 − 54 = 0

(𝜎 − 9)

(𝜎 − 9)(𝜎 2 − 6 𝜎 + 6) = 0

𝜎 2 − 6𝜎 + 6 = 0
𝜎1 = 9, 𝜎2 = 3 + √3 = 4.73 𝑘𝑠𝑖, 𝜎3 = 3 − √3 = 1.26 𝑘𝑠𝑖

𝜎𝑖

(𝜎𝑥 − 𝜎𝑖 ) 𝜏𝑥𝑦 𝜏𝑥𝑧

(𝜎𝑥 − 𝜎1 ) 𝜏𝑥𝑦
𝑎1 = | | = −11
𝜏𝑦𝑥 (𝜎𝑦 − 𝜎1 )
(𝜎𝑥 − 𝜎2 ) 𝜏𝑥𝑦
𝑎2 = | | = 0.66
𝜏𝑦𝑥 (𝜎𝑦 − 𝜎2 )
 (𝜎𝑥 − 𝜎3 ) 𝜏𝑥𝑦
𝑎3 = | | = −16.66
𝜏𝑦𝑥 (𝜎𝑦 − 𝜎3 )
𝜏𝑦𝑥 𝜏𝑦𝑧
𝑏1 = | | = −11
𝜏𝑧𝑥 (𝜎𝑧 − 𝜎1 )
𝜏𝑦𝑥 𝜏𝑦𝑧
𝑏2 = | | = −2.46
𝜏𝑧𝑥 (𝜎𝑧 − 𝜎2 )
𝜏𝑦𝑥 𝜏𝑦𝑧
𝑏3 = | | = 4.464
𝜏𝑧𝑥 (𝜎𝑧 − 𝜎3 )
(𝜎𝑦 − 𝜎1 ) 𝜏𝑦𝑧
𝑐1 = | | = −11
𝜏𝑧𝑦 (𝜎𝑧 − 𝜎1 )

(𝜎𝑦 − 𝜎2 ) 𝜏𝑦𝑧
𝑐2 = | | = 1.804
𝜏𝑧𝑦 (𝜎𝑧 − 𝜎2 )

(𝜎𝑦 − 𝜎2 ) 𝜏𝑦𝑧
𝑐3 = | | = 12.196
𝜏𝑧𝑦 (𝜎𝑧 − 𝜎3 )
1
𝑘1 = = 0.0524
√𝑎12 + 𝑏12 + 𝑐12

1
𝑘2 = = 0.320
√𝑎22 + 𝑏22 + 𝑐22

1
𝑘3 = = 0.047
√𝑎32 + 𝑏32 + 𝑐32

𝑙1 = 𝑘1 𝑎1 = −0.577, 𝑚1 = 𝑘1 𝑏1 = −0.577, 𝑛1 = 𝑘1 𝑐1 = −0.577

𝑙2 = 𝑘2 𝑎2 = 0.211, 𝑚2 = 𝑘2 𝑏2 = −0.7886, 𝑛2 = 𝑘2 𝑐2 = 0.577

𝑙3 = 𝑘3 𝑎3 = −0.7886, 𝑚3 = 𝑘3 𝑏3 = 0.2113, 𝑛3 = 𝑘3 𝑐3 = 0.577

QUESTION 4:
𝜖𝑎𝑣𝑔 = 2 × 10−3
 1 0.6 0.4
′
𝜖 = [0.6 0 0 ] × 10−3
0.4 0 −1

𝐸1 = 𝜖𝑥 + 𝜖𝑦 + 𝜖𝑧 = 6 × 10−3
1 2 2 2
𝐸2 = 𝜖𝑥 𝜖𝑦 + 𝜖𝑦 𝜖𝑧 + 𝜖𝑧 𝜖𝑥 − (𝛾𝑥𝑦 + 𝛾𝑦𝑧 + 𝛾𝑧𝑥 ) = 10.48 × 10−3
4
𝛾𝑥𝑦 𝛾𝑥𝑧
𝜖𝑋
2 2
|𝛾𝑦𝑧 𝛾𝑦𝑧 | 1 2 2 2
𝐸3 = 𝜖𝑦 = 𝜖𝑥 𝜖𝑦 𝜖𝑧 + (𝛾𝑥𝑦 𝛾𝑦𝑧 𝛾𝑧𝑥 − 𝜖𝑥 𝛾𝑦𝑧 − 𝜖𝑦 𝛾𝑧𝑥 − 𝜖𝑧 𝛾𝑥𝑦 )
|2 2| 4
𝛾𝑧𝑥 𝛾𝑧𝑦
𝜖𝑧
2 2
= 5.32 × 10−3

1
𝐸1′ = 0, 𝐸2′ = 𝐸12 − 𝐸2 = 1.52 × 10−6 ,
3
2 3 1
𝐸3′ = 𝐸1 − 𝐸1 𝐸2 + 𝐸3 = 0.36 × 10−9
27 3

𝐸1′ = 0
1 2 2 1 2
𝐸2′ = [(𝜖𝑥 − 𝜖𝑦 ) + (𝜖𝑦 − 𝜖𝑧 ) + (𝜖𝑧 − 𝜖𝑥 )2 ] + (𝛾𝑥𝑦 2
+ 𝛾𝑦𝑧 + 𝛾𝑧𝑥2
)
6 4
2(2𝜖𝑥 − 𝜖𝑦 − 𝜖𝑧 ) 3 𝛾𝑥𝑦 3𝛾𝑥𝑧
1
𝐸3′ = | 3𝛾𝑦𝑥 2(2𝜖𝑦 − 𝜖𝑧 − 𝜖𝑥 ) 3𝛾𝑦𝑧 |
6
3𝛾𝑧𝑦 3𝛾𝑧𝑦 2(2𝜖𝑧 − 𝜖𝑥 − 𝜖𝑦 )
3
−1
𝐸3′ 3 2
3𝛽 = cos ( ( ′ ) )
2 𝐸2

𝐸2′
𝜖1′ = 2 cos 𝛽 √ = 1.34 × 10−3 ,
3
 𝐸2′
𝜖2′ = 2 cos(𝛽 + 120°) √ = −0.25 × 10−3 ,
3

𝐸2′
𝜖3′ = 2 cos(𝛽 + 240°) √ = −1.09 × 10−3
3

QUESTION 5:
𝑅𝑜 =

𝑅1 =

Θ=

𝜇=

𝜎2

𝜎𝑦 (1 + 𝑁) 𝑅1 2𝑁
𝜎2 = [1 − ( ) ]
𝑁 𝑅𝑜

𝑁 = 𝜇 cot Θ = 0.15 cot 9 = 0.95

26(1 + 0.95) 2.6 2(0.95)

𝜎𝑡

−2 𝜇 𝐿
𝜎𝑡 = 𝜎𝑦 − (𝜎𝑦 − 𝜎2 ) 𝑒 𝑅1

−2×0.15×4
𝜎𝑡 = 26 − (26 − 13) 𝑒 2.6 = 17.8 𝐾𝑔/𝑚𝑚2

𝐹 = 𝑇𝑜𝑡𝑎𝑙 𝐷𝑟𝑎𝑤𝑖𝑛𝑔 𝑙𝑜𝑎𝑑 = 𝜎𝑡 × 𝜋𝑅12 = 17.8 × 𝜋 × 2.62 = 377.8 𝐾𝑔