Solutions-Final Exam June 2019

1. Describe the effect of strain rate in metal forming processes & show mathematically &
graphically how it affects flow stress. [3]
Flow stress of a metal is a function of temperature. Flow stress depends on strain rate.

έ= v/h where έ= strain rate s-1 h=instantaneous height of the work piece being deformewd
v= speed of deformation
At the temperature of hot working, the flow stress depends on strain rate. The effect of strain rate
on strength properties is known as strain rate sensitivity As the strain rate is increased, resistance
to deformation increases ----Equation 18.4
where C is strength constant and m is strain rate sensitivity exponent
 2. Explain why there might be a change in the density of a forged product as compared to
that of the cast blank.[2]
If the original material has porosity, such as from poor casting with porosity due to gases
or shrinkage cavities, its density will increase after forging because the pores will close
under the applied compressive stresses.
On the other hand, the original blank may be free of porosity but due adverse material
flow, and state of stress during plastic deformation cavities may develop ( similar to
voids that developed in the necked region of a tensile specimen. Thus density will
decrease after forging due to void formation.
3. A cold heading operation is performed to produce the head on a steel nail. The strength
coefficient for this steel is K = 550 MPa, & the strain hardening exponent n = 0.24.
Coefficient of friction at the die-work interface = 0.10. The wire stock out of which the nail
is made is 4.75 mm in diameter. The head is to have a diameter = 9.5 mm & a thickness = 1.5
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.
Answer:
𝐷 2 ℎ ∗9.52 ∗1.5
a. 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑛𝑎𝑖𝑙 ℎ𝑒𝑎𝑑 𝑣 = 𝑓4 𝑓 = = 106.3 𝑚𝑚3
4
𝐷𝑜 2 ∗4.752
𝐴𝑟𝑒𝑎 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝐴𝑜 = = = 17.7 𝑚𝑚2
4 4
𝑉 106.3
𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑝𝑟𝑜𝑗𝑒𝑐𝑡𝑖𝑜𝑛 ℎ𝑜 = = = 6 𝑚𝑚
𝐴𝑜 17.7
ℎ𝑜 6
b) 𝜖 = 𝑙𝑛 ℎ = 1.5 = 1.38
𝑓
𝑌𝑓 = 𝐾 ∈𝑛 = 550 ∗ 1.380.24 = 595 𝑀𝑃𝑎
𝐷𝑓 2  ∗ 9.52
𝐴𝑟𝑒𝑎 𝐹𝑖𝑛𝑎𝑙 𝐴𝑓 = = = 70 𝑚𝑚2
4 4
0.4𝜇𝐷𝑓 0.4 ∗ 0.1 ∗ 9.5
𝐹𝑜𝑟𝑔𝑖𝑛𝑔 𝑠ℎ𝑎𝑝𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 𝐾𝑓 = 1 + = 1+ = 1.25
ℎ𝑓 1.5
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑝𝑢𝑛𝑐ℎ 𝑓𝑜𝑟𝑐𝑒 𝐹 = 𝐾𝑓 ∗ 𝑌𝑓 ∗ 𝐴𝑓 = 1.25 ∗ 595 ∗ 71 = 52872 𝑁
4.. What are the two parameters on which maximum possible draft in rolling operation
depends? Define what do you mean total draft in flat rolling operation, and explain what you
will do when total draft is larger than maximum possible draft
- The two parameters are friction coefficient of the work material, and the radius of
Roller
- It is the amount of thickness required to be reduced by flat rolling.
- When total draft is larger than the permissible draft in a single pass, the number of
passes will be increased to more than one.
5. Extrusion ratio
𝜋𝐷2 𝜋 ∗ 1202
𝐴𝑜 = = = 11309.7 𝑚𝑚2
4 4
𝜋(102 − 52 )
𝐴𝑓 = 2 ∗ (80 ∗ 10) + (60 ∗ 10) + 2 ∗ (5 ∗ 10) + 2 ∗ [ ]
4
𝐴𝑓 = 1600 + 600 + 100 + 235.6 = 2535.6 𝑚𝑚2
𝐴𝑜 11309.7
𝑅𝑥 = = = 4.46
𝐴𝑓 2535.6
True strain (homogeneous deformation)
𝜖 = 𝑙𝑛𝑅𝑥 = 𝑙𝑛4.46 = 1.49
Extrusion strain (Johnson equation)
𝜖𝑥 = 𝑎 + 𝑏𝑙𝑛𝑅𝑥 = 0.8 + 1.4 ∗ 1.49 = 2.89
𝐾𝜖 𝑛 400 ∗ 1.490.13
𝑌𝑓 = = = 372.8 𝑀𝑝𝑎
1+𝑛 1 + 0.13
𝑃 = 𝑌𝑓 𝜖𝑥 = 372.8 ∗ 2.89 = 1077.4 𝑤
Average ram force
𝐹𝑎𝑣 = 𝑃𝐴𝑜 = 1077.4 ∗ 11309.7 = 12184980𝑁 = 12𝑀𝑁
Length of the extruded section if the butt remaining in the container at the end of the ram stroke
is 25 mm.
𝑉𝑜𝑙𝑢𝑚𝑒𝑖𝑛𝑖𝑡𝑖𝑎𝑙 = 𝑉𝑜𝑙𝑢𝑚𝑒𝑓𝑖𝑛𝑎𝑙
𝐴𝑜 𝐿𝑜 = 𝐴𝑓 𝐿𝑓 ∗ 𝐴𝑜 𝐿𝑜
11309.7 ∗ 100 = 2535.6 ∗ 𝐿𝑓 + 11309.7 ∗ 25
1130970 = 2535.6𝐿𝑓 + 282740
848230
𝐿𝑓 = = 334.4 mm
2535.6

Q.6.
 7. LT = L1 + BA1 + L2 + BA2 + L3 + BA3 + L2 + BA4 + L5
2𝜋𝜃 2𝜋𝜃
= 62-R+ (𝑅1 + 𝐾𝑡) +25-T-R-R+ (𝑅2 + 𝐾𝑡) +50-T-R-R-T+
360 360
2𝜋𝜃 2𝜋𝜃
(𝑅3 + 𝐾𝑡) +25-T-R-R + (𝑅4 + 𝐾𝑡) +R-200
360 360
2𝜋𝜃 2𝜋𝜃
= 62-2+ (𝑅1 + 𝐾𝑡) +25-1.5-2-2+ (𝑅2 + 𝐾𝑡) +50-1.5-2-2-1.5+
360 360
2𝜋𝜃 2𝜋𝜃
(𝑅3 + 𝐾𝑡) +25-1.5-2-2 + (𝑅4 + 𝐾𝑡) +2-200
360 360
2𝜋𝜃
= 60 + 4* 360 (2 + 0.33 ∗ 1.5) + 19.5 + 43 + 19.5 + 198
= 60 + 4*3.9 + 19.5 + 43 + 19.5 + 198
= 60 + 15.68+ 19.5 + 43 + 19.5 + 198
LT = 355.67 mm

𝐾𝑏𝑓∗𝑇𝑆∗𝑊∗ 𝑡 2 0.33 ∗ 180 ∗ 75 ∗ 1.52

𝑭𝑬𝒅𝒈𝒆 𝒃𝒆𝒏𝒅𝒊𝒏𝒈= = = 4009.5 𝑁 = 4 𝐾𝑁
𝐷 2.5
1. 8. The foreman in the press working section comes to you with the problem of a blanking
operation that is producing parts with excessive burrs.
a. What are the possible reasons for the burrs, and
b. What can be done to correct the condition?
9. Distinguish between the sheet metal punching and blanking and Engineering analysis of sheet
metal cutting to design punch and die size for punching and blanking operation with the help of
sketch.
10. a) Explain the general working principle of Arc Welding process and differentiate the two
main Arc Welding types: Shield Metal Arc Welding and Gas Metal Arc Welding
8 b) Define root of the joint, groove and penetration
c.Designate both groove welds (single VEE groove and BUTT and single TEE grove fillet)
using standard arc welding symbol including weld size, length and pitch

d) Describe the welding variables by associating them.

Heat supplied, Power density……….
e) What are the possible defects in the welding process ( List some of them) and their
possible remedy.
Porosity, Slag inclusions ,spatters, cracks, Incomplete fusion and penetration……
f) Explain the working principles of spot resistance welding and discuss in detal yhe
parameters that govern the process.