Madan Mohan Malviya University of Technology

Gorakhpur, Uttar Pradesh

Department of Mechanical Engineering
(Unit-1, Tutorial-1)
Subject- Manufacturing Science (BME-254) Semester: 4th
Session: 2023-24

Q1. What do you understand by Manufacturing? What is the importance of manufacturing in

our society and classify manufacturing processes in various aspects.

Q2. A metal has a flow curve with strength coefficient 850MPa and strain hardening exponent
0.30. A tensile specimen of metal with gauge length 100 mm is stretched to a length 157
mm. Determine the flow stress at new length and average flow stress that the metal has
been subjected to during the deformation.

Q3.A particular metal has a flow curve with strength coefficient 35,000 lb/inch 2 and strain
hardening exponent 0.26. A tensile specimen of metal with gauge length 2 inch is
stretched to a length 3.3 inch. Determine the flow stress at new length and average flow
stress that the metal has been subjected to during the deformation.

Q4. In a tensile test, two pairs of values of stress and strain were measured for the specimen
metal after it had yielded: (a) true stress 217MPa and true strain 0.35 and (b) true stress
259MPa and true strain 0.68. Based on these data points, determine the strength
coefficient and strain hardening exponent.

Q5. If σ=¿ ¿700❑ MPa, (a) Find the yield strength after 50% of cold work.
0.2

(b) A specimen is cold worked by an unknown amount and then again cold worked 15 % more
and found to have yield of 525MPa. What is unknown amount of cold work?

Q6. During a tensile test, the tensile strength was found to be 340MPa. This was recorded at
30% elongation. Find the value of n and K.
Q7. A material is being deformed in tension and strain hardening occurs linearly as
σ =σ +1.35 σ . ε at what strain necking begins.

Q8. The flow stress (in MPa) of a material is given by σ=¿ ¿500❑ ,where ε is true strain. The
0.1

young modulus of elasticity of material is 200GPa. A block of thickness 100 mm made of

this material is compressed to 95 mm thickness and then the load is removed. The final
dimension of the block (in mm) is.

Q9. The true stress (σ ) and true strain (ε) diagram of a strain hardening material is shown in
figure. First, there is loading up to point A i.e. up to stress of 500MPa and strain of 0.5,
then from point A, there is unloading up to point B i.e. to stress of 100MPa. Given that the
Young’s modulus E = 200GPa, the natural strain at point B (εB) is.

Q10. Consider the strain – stress curve for an ideal elastic-plastic strain hardening metal as
shown in figure. The metal was loaded in uniaxialy tension starting from O. Upon loading,
the stress-strain curve passes through initial yield point at P, and then strain hardens to
point Q, the specimen was unloaded to point R, where the stress is zero. If the same
specimen is reloaded in tension from point R, the value of stress at which the materials
yields again is in MPa.
Q11. Calculate the length of sheet required for making the component as shown in figure, out
of 3 mm C20 steel sheet.

Q12. Estimate the force required for a 90 degree bending of St 50 steel of 2mm thickness in V-
die. The die opening can be taken as 8 times the thickness. The length of bent part is 1 m.
Given UTS for St 50 is 500 MPa.

Q13. Calculate the bending force required for a 1.5 mm C50 steel sheet of 1m width to be bent
in a wiping die. The die radius used is 3 mm. Given UTS for C50 steel is 800MPa.

Q14. As shown in the figure, the cross-section of bent steel strip represents the bend is of
375mm length and 90 degree angle. Calculate the dimension of steel before bending and
force required to bend it using a V-die of opening 16 times sheet thickness. The tensile
strength of material is 630 N/mm2.
Q15. For the mild steel product shown in the figure, what is minimum possible corner radius r
if the fracture strain (εfrac) 0.2 for the given material.

Using the data E = 207kN/mm2 ,µ = 0.1, l = 25mm, σye = 345 N/mm2, n = 517 N/mm2, and
considering r to be minimum, determine (a) the maximum bending force, (b) the required
punch angle, and (c) the stock length.

Q16. If a fully work hardened Aluminium blank of 100 mm diameter and thickness 1.2 mm.
Sheet has a mean flow stress of 350 MPa. It is deep drawn to a cylindrical cup of 50 mm mid
wall diameter. The blank holding force is 30 kN, coefficient of friction is 0.1. Take the die
curvature radius as 8 times the sheet thickness. Determine the final cup height and
approximate load.

Q17. A cylindrical cup without flange is to be drawn from a 2 mm thick sheet. The cup shall
have 15 mm diameter and 40 mm height. Reduction ratio is the first and subsequent draws
may not exceed 40 % and 15 % respectively. Determine the blank size and the number of
draws necessary.
 Q18. A strip with cross-section of 150*6 mm2 is rolled with 20% reduction in area using 400
mm dia steel rolls. Before and after rolling, the shear yield stress of material is 0.35kN/mm 2
and 0.4kN/mm2 respectively. Calculate (a) Final strip thickness (b) Average shear yield stress
(c) Angle subtended by deformation zone at roll centre (d) The location of neutral point and
thickness of neutral plane. Assume µ = 0.1.

Q19. Derive the following expression for non dimensional rolling pressure in the regions
before and after neutral point.

σ xi
( )
P
2K
=¿
(1- 2 K )*e
µ(¿−λ)¿

σ xi
( )P
2K
=¿ µλ
(1- 2 K )*e )

Q20. Derive the following expression for drawing stress σ xa for wire drawing operation.

σxa
=(1−{})
2k

Where, B = µ cotα ; α = Semi die angle; k = shear strength of wire

Da = Diameter of wire at exit of die ; Db = Diameter of wire at entry of die

Q21. A steel wire is drawn from an initial diameter of 12.7 mm to a final diameter of 10.2 mm
at a speed of 90m/min. The half-cone angle of the die is 6 0 and the coefficient of friction at
the job-die interface is 0.1. A tensile test on the original steel specimen gives a tensile
yield stress 207 N/mm2. A similar specimen shows a tensile yield stress of 414 N/mm 2 at a
strain of 0.5. Assuming a linear stress – strain relationship for the material, determine the
drawing power and the maximum possible reduction with the same die. No back tension is
applied.

Q22. Assume the frictional work to be 20 % of the ideal work, what will be the maximum

reduction per pass for a wire drawing operation with strain hardening curve σ=¿ ¿350❑
0.3

Q23. A wire of 0.1 mm diameter is drawn from a rod of 15 mm diameter dies giving reduction
of 20 % , 40 %, and 80 % are available. For minimum error in the final size, the number of
stages and reduction at each stage respectively would be
Q24. In a wire drawing operation, diameter of a steel wire is reduced from 10 mm to 8 mm.
The mean flow stress of the materials is 400 MPa. The ideal force required for drawing
(ignoring friction and redundant work) is

Q25. In a multi-pass operation, a round bar of 10 mm diameter and 100 mm length is reduced
in cross-section by drawing it successfully through a series of seven dies of decreasing exit
diameter. During each of these drawing operations, the reduction in cross-section area is
35 %. The yield strength of material is 200 MPa. Ignore strain hardening.

Q26. In a Two-stage wire drawing operation, the fraction reduction (ratio of change in cross-
section area to initial cross-sectional area) in the first stage is 0.4. The fraction reduction in
the second stage is 0.3. The overall fraction reduction is