A cold heading operation is performed to produce the head on a steel nail. The strength coefficient for this steel is 600 MPa, and the strain hardening exponent is 0.22. Coefficient of friction at the die‑work interface is 0.14. The wire stock out of which the nail is made is 5.00 mm in diameter. The head is to have a diameter of 9.5 mm and a thickness of 1.6 mm. The final length of the nail is 120 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 f

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Forming and Shaping

Metal forming is a category of metalworking process through which the material can be given the desired shape and size by subjecting it to plastic deformation, where the component undergoes bulk deformation process upon application of loads. Unlike the shearing and machining process, the material does not undergo up to a failure point as indicated in the stress-strain curve. Hence, the stresses induced during the forming process are greater than yield strength but less than the failure strength of the material. The process does not lead to the loss of material, so it can be said to be an economical process. During forming, the material is subjected to tensile forces, compressive forces, bending, and shearing loading conditions. The material should possess the property of ductility to undergo the forming process.