A cylindrical part is warm upset forged in an open die. The initial diameter is 50 mm and the initial height is 40 mm. The height after forging is 30 mm.

Q: A plate of 270 mm wide and 25 mm thick from carbon steel. A two-high rolling mill is used to reduce…

A: (a) Calculate the contact length of arc. Lp=R∆H=60025-20=54.77 mm Calculate the true strain.…

Q: A cylindrical billet that is 100 mm long and 50 mm in diameter is reduced by indirect (backward)…

A: Dear student                    According to the guidelines I am allowed to answer only first three…

Q: An austenitic stainless steel plate with a width of 100 mm, a length of 150 mm and a thickness of 50…

A: Given: The width of the plate, w = 100 mm The length of the plate, L = 150 mm The height of the…

Q: c) A flat rolling operation is being carried out where the roll radius is 200 mm and the roll…

A: A rolling force is applied by rollers to the workpiece so as to reduce its thickness Maximum…

Q: 5.1 Calculate the final bend radius for a 3 mm thick 6061 T6 aluminum plate that is formed using a…

A: Given : Thickness = 3  mm punch = 8 mm To find: Final radius

Q: A round wire made from 1020 carbon steel is being drawn from a diameter of 12.5 mm to  9.5 mm in a…

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Q: A 3in long and 1in diameter billet is extruded in a direct extrusion operation with an rx = 4.0. The…

A: Write the extrusion ratio.   rx=4   Write the length and diameter of the billet.   L=3 inD=1 in…

Q: 4) mm in diameter. It is reduced by indirect extrusion to a 30 mm diameter. Die angle = 90°. In the…

A: As per our guidelines we are supposed to solve only 3 subparts if multiple subparts are asked .…

Q: 3. Compare open-die forging, closed die forging, and flashless forging in detail. Explain procedures…

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Q: Estimate the power for annealed low carbon steel strip 200 mm wide and 10 mm thick, rolled to a…

A: Rolling is a metal forming process in which a material is plastically deformed by passing it between…

Q: A solid cylindrical slug made of 304 stainless steel is 150 mm in diameter and 100 mm high. It is…

A: Given:Initial diameter of cylinder, do=150 mmInitial height of the cylinder, ho=100 mmDiameter after…

Q: A round wire made from 1020 carbon steel is being drawn from a diameter of 12.5 mm to 9.5 mm in a…

A: Empirical relation for F in terms of yield strength, area ratio, friction coefficient and die angle…

Q: Illustrate the advantages of direct extrusion on indirect extrusion

A: The direct extrusion process is the most well-known extrusion used in the expulsion business. It…

Q: Estimate the power for annealed low carbon steel strip 200 mm wide and 10 mm thick, rolled to a…

A: Rolling is a metal forming process in which a material is plastically deformed by passing it between…

Q: A spool of wire has a starting diameter of 2.5 mm. It is drawn through a die with an opening that is…

A: givenspool of wire has a starting diameter di= 2.5 mma die with an opening that is df= 2.1…

Q: A low-carbon steel plate is 300 mm wide and 25 mm thick. It is reduced in one pass in a two-high…

A: The width of the steel plate is w=300 mm. The initial thickness of the steel plate is ti=25 mm. The…

Q: A hot rolling operation is being carried out on 250 mm wide and 25mm thick low carbon steel…

A: Calculate the final thickness. hf=1-0.2ho   =0.8×25   =20 mm Calculate the strain. Strain ε=lnhohf…

Q: required at the moment of reaching the yield point (ℇ = 0.002) b) Force required when you have a…

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Q: If a different piece of the cold rolled sheet of part (a) is 0.54 m wide and rolled at 6200 cm/min…

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Q: What are the advantages of a counterblow or impact forging machine? What are some of the properties…

A: The counterblow hammers are used in the process of forging for better forging energy levels. The…

Q: Write down what you know about extrusion defects or rolling defects

A: Let us discuss about defects in rolling or extrusion processes.

Q: In open-die forging, a disc of diameter 200 mm and height 60 mm is compressed without any barreling…

A: Given:D1=200 mml1=60 mmD2=400 mm

Q: A steel sheet has R values of 1.0, 1.5, and 2.0 for the 0°, 45° and 90° directions to rolling,…

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Q: Describe the effect that extrusion has on material properties with examples

A: Extrusion is a process that confines a metal in a closed cavity by allowing it to flow from only a…

Q: A cylindrical billet that is 100 mm long and 50 mm in diameter is reduced by indirect (backward)…

A:

Q: Assuming that an average forging pressure of 340 Mpa is required,what is the largest closed-die…

A: Given: P=340 MPa F=350 MN

Q: Estimate the power for annealed low carbon steel strip 200 mm wide and 10 mm thick, rolled to a…

A: Rolling is a metalworking process. In rolling, metal is deformed by passing them through rollers…

Q: A 250 mm wide strip of 20 mm thickness is reduced to 18 mm in a single pass through a rolling…

A: In a single pass, a 250 mm wide strip with a 20 mm thickness is reduced to 18 mm using a rolling…

Q: A cylindrical part is warm upset forged in an open die. The initial diameter is 45 mm and the…

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Q: A upset forging operation is performed in an open die. The init 63 mm, and ho = 100 mm. The part is…

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Q: Estimate the power for annealed low carbon steel strip 200 mm wide and 10 mm thick, rolled to a…

A: Rolling is a metal forming process in which a material is plastically deformed by passing it between…

Q: Draw and explain drop forging process. Write any three common forging materials and mention its…

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Q: An open die forging operation is performed to produce a steel cylinder with a diameter o 9.7mm and a…

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Q: A cold heading operation is performed to produce the head on a steel nail. The strength coefficient…

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Q: Using open-die forging operation, a solid cylindrical piece of S.S. having 100 mm diameter and 72 mm…

A: Forging is a metal-shaping method in which metal is shaped by applying focused compressive stresses.…

Q: A hot upset forging operation is performed in an open die. The initial size of the workpart is: Do =…

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Q: A solid cylindrical work piece is reduced in height by an open die forging process using flat dies…

A: Given : initial diameter = 100 mm initial height = 60 mm final height = 0.85×60 = 51 mm coefficient…

Q: . A component is designed to be hot forged in an impression die. The projected area of the  product…

A: Given data: The shape factor for the simple work with flash chamber varies between 5 to 8. Taking…

Q: Describe the method of improving the forging die life and the advantages of improving the forging…

A: Dietary Restrictions Forging is a forging technique in which dies move near each other and…

Q: Explain the difference between Flat Rolling and Shape Rolling processes.…

A: Flat rolling: In flat rolling operation, the material is rolled between normal rolls. The desired…

Q: Explain the differences between Forward Extrusion and Reverse Extrusion processes

A: Forward Extrusion. The movement of ram and stock is in the same direction, so it is known as forward…

Q: A cylindrical billet that is 100 mm long and 50 mm in diameter is reduced by indirect (backward)…

A:

Q: A steel billet with a rectangular cross section is being forged using a die with a width of 84.5 mm.…

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Q: The team performs a cold heading operation to produce the head on a steel nail. The strength…

A: Given ,   K = 550MPa                 n = 0.24                μ = 0.1diameter of wire stock, d = 4.75…

Q: H.W Example: A 300 mm wide strip 25 mm thick is fed through a rolling mill with two powered rolls…

A: As per given Question  W=300mm Thickness =25mm Radius=250mm K=275mpa Reducced thickness =22mm…

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.