Null 1

Model Answer
Metal Forming (2023)
QUESTION 1:
𝜎 = 𝐾 𝜖𝑛
𝑃 = 𝜎𝐴 𝑑𝑃 = 0
𝜎𝑑𝐴 + 𝐴𝑑𝜎 = 0
𝑑𝜎 𝑑𝐴
= −
𝜎 𝐴
𝑑𝐴
𝑑𝜖 = −
𝐴
𝑑𝜎
=𝜎
𝑑𝜖
𝑑𝜎
= 𝑛 𝐾 𝜖 𝑛−1
𝑑𝜖
𝐾 𝜖 𝑛 = 𝑛 𝐾 𝜖 𝑛−1
𝑛
𝐾 𝜖 𝑛 = 𝐾𝜖 𝑛
𝜖
𝜖=𝑛
𝐴𝑜 − 𝐴 𝐴 𝐴
𝑟= =1− =1−
𝐴𝑜 𝐴𝑜 exp(𝜖)
1
exp(𝜖) =
1−𝑟
1 1
𝜖 = ln ( ) 𝑟 = 0.4 𝜖 = ln ( ) = 0.511
1−𝑟 1−0.4
𝜎 = 725 𝜖 0.21 = 725 × 0.5110.21 = 629.615
QUESTION 2:
𝜎𝑥 = −19 𝜏𝑥𝑦 = −4.7 𝜏𝑥𝑧 = 26.45

𝜏𝑦𝑥 = −4.7 𝜎𝑦 = 4.6 𝜏𝑦𝑧 = 11.8
𝜏𝑧𝑥 = 26.45 𝜏𝑧𝑦 = 11.8 𝜎𝑧 = −8.3
2
𝜏𝑥𝑦 = 22.09
2
𝜏𝑦𝑧 = 139.24
2
𝜏𝑧𝑥 = 699.6025
𝜏𝑥𝑦 𝜏𝑥𝑧 𝜏𝑦𝑧 = − 312.16546
𝜎𝑥 𝜎𝑦 𝜎𝑧 = 725.42
𝐼1 = 𝜎𝑥 + 𝜎𝑦 + 𝜎𝑧 = −22.7
2 2 2
𝐼2 = 𝜎𝑥 𝜎𝑦 + 𝜎𝑥 𝜎𝑧 + 𝜎𝑦 𝜎𝑧 − 𝜏𝑥𝑦 − 𝜏𝑥𝑧 − 𝜏𝑦𝑧 = −8028.8125
2 2 2
𝐼3 = 𝜎𝑥 𝜎𝑦 𝜎𝑧 + 2 𝜏𝑥𝑦 𝜏𝑥𝑧 𝜏𝑧𝑦 − 𝜎𝑥 𝜏𝑦𝑧 − 𝜎𝑦 𝜏𝑥𝑧 − 𝜎𝑧 𝜏𝑥𝑦 = −2597.6785
𝐼12
𝑅 = − 𝐼2 = 1000.6
3
𝑅3
𝑇 = √ = 6091.1
27
𝐼2 𝐼3 2𝐼13
𝑄= − 𝐼3 − = 9735.5
3 27
𝑅
𝑆 = √ = 18.2627
3
−𝑄
𝛼 = arccos ( ) = 143.05 °
2𝑇
𝛼 𝐼1
𝜎𝑎 = 2𝑆 (cos ( )) + = 17.0232 𝑀𝑃𝑎
3 3
𝛼 𝐼1
𝜎𝑏 = 2𝑆 (cos ( + 120°)) + = −43.2513 𝑀𝑃𝑎
3 3
𝛼 𝐼1
𝜎𝑐 = 2𝑆 (cos ( + 240°)) + = 3.5281 𝑀𝑃𝑎
3 3
𝜎1 = 17.0232 𝑀𝑃𝑎, 𝜎2 = 3.5281 𝑀𝑃𝑎 , 𝜎3 = −43.2513 𝑀𝑃𝑎
𝜎𝑖
(𝜎𝑥 − 𝜎𝑖 ) 𝜏𝑥𝑦 𝜏𝑥𝑧

| 𝜏𝑦𝑥 (𝜎𝑦 − 𝜎𝑖 ) 𝜏𝑦𝑧 |
𝜏𝑧𝑥 𝜏𝑧𝑦 (𝜎𝑧 − 𝜎𝑖 )
(𝜎𝑥 − 𝜎1 ) 𝜏𝑥𝑦
𝑎1 = | | = −175.36
𝜏𝑦𝑥 (𝜎𝑦 − 𝜎1 )
𝑎2 = | | = 151.92
𝑎3 = | | = −1533.23
𝜏𝑦𝑥 𝜏𝑦𝑧
𝑏1 = | | = −193.10
𝜏𝑧𝑥 (𝜎𝑧 − 𝜎1 )
𝑏2 = | | = −256.52
𝑏3 = | | = −476.38
(𝜎𝑦 − 𝜎1 ) 𝜏𝑦𝑧
𝑐1 = | | = −273.13
𝜏𝑧𝑦 (𝜎𝑧 − 𝜎1 )
𝑐2 = | | = 83.81
𝑐3 = | | = 1321.13
1
𝑘1 = = 0.002648
√𝑎12 + 𝑏12 + 𝑐12
1
𝑘2 = = 0.003230
√𝑎22 + 𝑏22 + 𝑐22
1
𝑘3 = = 0.000480
√𝑎32 + 𝑏32 + 𝑐32
𝑙1 = 𝑘1 𝑎1 = −0.46431, 𝑚1 = 𝑘1 𝑏1 = −0.51127, 𝑛1 = 𝑘1 𝑐1 = −0.72320
𝑙2 = 𝑘2 𝑎2 = 0.49056, 𝑚2 = 𝑘2 𝑏2 = −0.82832, 𝑛2 = 𝑘2 𝑐2 = 0.27063
𝑙3 = 𝑘3 𝑎3 = −0.73741, 𝑚3 = 𝑘3 𝑏3 = −0.22912, 𝑛3 = 𝑘3 𝑐3 = 0.63540
QUESTION 3:
35 (30 𝑐𝑚)⁄
𝜎1 = 𝑃𝑟⁄𝑡 = 𝑡 = 𝜎𝑚𝑎𝑥
35 (30 𝑐𝑚)⁄ 1
𝜎2 = 𝑃𝑟⁄2𝑡 = 𝑡 = 2 𝜎𝑚𝑎𝑥
𝜎3 ≈ 0
𝜎1 = 700 𝑀𝑃𝑎
(35 𝑀𝑃𝑎)(30 𝑐𝑚)

𝑡= = 1.5 𝑐𝑚
(700 𝑀𝑃𝑎)
𝜎1 − 𝜎3 = 2𝑘 = 2(280) = 560 𝑀𝑃𝑎

(35 𝑀𝑃𝑎)(30 𝑐𝑚)
𝑡= = 1.875 𝑐𝑚
(560 𝑀𝑃𝑎)
(700 𝑀𝑃𝑎)(30 𝑐𝑚)⁄

𝜎1 = 𝜎𝑦 = 1.5 𝑐𝑚 = 1400 𝑀𝑃𝑎
1
𝜎1 = 𝜎𝑚𝑎𝑥 , 𝜎2 = 𝜎𝑚𝑎𝑥 𝜎3 ≈ 0
2
(𝜎1 − 𝜎2 )2 + (𝜎2 − 𝜎3 )2 + (𝜎3 − 𝜎1 )2 = 2𝜎𝑦2 = 6𝑘 2
2 2
1 1
( 𝜎𝑚𝑎𝑥 ) + ( 𝜎𝑚𝑎𝑥 ) + (𝜎𝑚𝑎𝑥 )2 = 2𝜎𝑦2
2 2
3 2
𝜎 = 𝜎𝑦2
4 𝑚𝑎𝑥
√3
𝜎𝑦 = 𝜎𝑚𝑎𝑥 = √3(700 𝑀𝑃𝑎)(30 𝑐𝑚)⁄2 × 1.5 𝑐𝑚 = 1714.46 𝑀𝑃𝑎
2
QUESTION 4:
𝐻𝑜 is initial thickness of plate = 20 mm
𝐻1 is Final thickness of plate = 14 mm.
Draft = Δ𝐻 = 𝐻𝑜 − 𝐻1 = 20 − 14 = 6 𝑚𝑚.
480
𝑅 is the radius of the roll = = 240 𝑚𝑚.
2
1) To find the angle of bite 𝛼 we use the equation Δ𝐻 = 2 𝑅 (1 − cos 𝛼).
6 = 2 (240)(1 − cos 𝛼)
6
cos 𝑎 = 1 − ( )
480
𝑎 = 9𝑜
2) To find coefficient of friction 𝜇.
𝜇 = tan 𝑎 = tan 9 = 0.158
3) To find the position of neutral plane 𝐻𝑥
2𝜇𝐿
𝑛=
Δ𝐻
𝐿 = √𝑅Δ𝐻 = √240 × 6 = 37.94 𝑚𝑚
2 × 0.158 × 37.94
𝑛= =2
6
For neutral section location
𝐻𝑥 𝑛 𝐻𝑜 𝑛
(𝑛 + 1) ( ) − 1 = (𝑛 − 1) ( ) + 1
𝐻1 𝐻𝑥
𝐻𝑥 2 20 2
(2 + 1) ( ) − 1 = (2 − 1) ( ) + 1
14 𝐻𝑥
𝐻𝑥 = 15.3 𝑚𝑚
4) To find backward slip 𝐵𝑆
𝑉 − 𝑉𝑜 𝑉𝑜 𝐻𝑥 15.3 4.7
𝐵𝑆 = =1− =1− =1− = = 23.5 %
𝑉 𝑉 𝐻𝑜 20 20
5) To find forward slip 𝐹𝑆
𝑉1 − 𝑉 𝑉1 𝐻𝑥 15.3 15.3 1.3
𝐹𝑆 = = −1= −1= −1= −1= = 0.92
𝑉 𝑉 𝐻1 14 14 14
= 9.2 %
6) To find maximum pressure 𝑃𝑥𝑚𝑎𝑥
𝑚𝑎𝑥
𝜎𝑦 𝐻𝑜 𝑛 12 20 2
𝑃𝑥 = [(𝑛 − 1) ( ) + 1] = [(2 − 1) ( ) + 1]
𝑛 𝐻𝑥 2 15.3
= 16.46 𝑘𝑔/𝑚𝑚2
QUESTION 5:

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Model Answer

Metal Forming (2023)

𝜎 = 725 𝜖 0.21 = 725 × 0.5110.21 = 629.615

𝜎𝑥 = −19 𝜏𝑥𝑦 = −4.7 𝜏𝑥𝑧 = 26.45

𝜎1 = 17.0232 𝑀𝑃𝑎, 𝜎2 = 3.5281 𝑀𝑃𝑎 , 𝜎3 = −43.2513 𝑀𝑃𝑎

(𝜎𝑥 − 𝜎𝑖 ) 𝜏𝑥𝑦 𝜏𝑥𝑧

𝑙1 = 𝑘1 𝑎1 = −0.46431, 𝑚1 = 𝑘1 𝑏1 = −0.51127, 𝑛1 = 𝑘1 𝑐1 = −0.72320

𝑙2 = 𝑘2 𝑎2 = 0.49056, 𝑚2 = 𝑘2 𝑏2 = −0.82832, 𝑛2 = 𝑘2 𝑐2 = 0.27063

𝑙3 = 𝑘3 𝑎3 = −0.73741, 𝑚3 = 𝑘3 𝑏3 = −0.22912, 𝑛3 = 𝑘3 𝑐3 = 0.63540

(35 𝑀𝑃𝑎)(30 𝑐𝑚)

𝜎1 − 𝜎3 = 2𝑘 = 2(280) = 560 𝑀𝑃𝑎

(700 𝑀𝑃𝑎)(30 𝑐𝑚)⁄

(𝜎1 − 𝜎2 )2 + (𝜎2 − 𝜎3 )2 + (𝜎3 − 𝜎1 )2 = 2𝜎𝑦2 = 6𝑘 2

1) To find the angle of bite 𝛼 we use the equation Δ𝐻 = 2 𝑅 (1 − cos 𝛼).

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