A solid cylindrical work piece is reduced in height by an open die forging process using flat dies on a mechanical press, powered by a 20 kW motor which operates at 35 strokes per minute with a stroke length of 160 mm. The work piece is 60 mm high and 100 mm in diameter and is to be reduced in height by 15%. The coefficient of friction during the operation is 0,18. Calculate the flow stress of work piece material if the press is set to operate at  90% of its maximum capacity.

Q: Explain why and how various factors influence springback in bending of sheet metals.

A: Plastic deformation in the material is always followed by the elastic recovery, since the elastic…

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:

Q: A hard metal ball of 10mm diameter is slid across a soft metal surface and produces a groove of 3mm…

A:

Q: A connecting rod is designed for hot forging in a printing die. The projected area of the part is…

A: Given Data Ap=6500 mm2 A=9000mm2 σf=75Mpa To Find the maximum force required to execute the…

Q: During a hot upset forging process the starting diameter of work part is 36 mm, and starting height…

A: Given, Initial radius, r1=18 mmFinal radius, r2=35 mmInitial height, h1=33 mmYf=45 MPaμ=0.2

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: Calculate the power required to roll an 8650 steel strip, 140 mm wide and 20 mm thick to a thickness…

A:

Q: A strip with a cross section 120 mm x 6 mm is being rolled with 20% reduction area, using rolls of…

A:

Q: A cylindrical working part is subjected to a forging landfall operation. The blank is 3.0 in. high…

A: volume of workpiece=π4×22×3=9.4247 in3

Q: Assume that you are carrying out a sheet forming operation and you find that tl material is not…

A:

Q: Example 3: A hydraulic forging press is capable of exerting a maximum force 1,000,000 N. A…

A:

Q: Compare hot and cold rolling products in terms of surface quality, mechanical properties, force…

A: Hot rolling process:- In this process metal will roll above recrystallisation temperature. Cold…

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

A:

Q: In blanking operation, if the final blank diameter is 200 mm & the clearance is 1.5 mm, then the Die…

A: Answer 8: In the blanking operation, the clearance is provided on the punch not on die so die and…

Q: Explain the differences that you may observe between products made of sheet metals and those made by…

A: The main difference between the products made of sheet metals and those made by casting or forging…

Q: A 40 mm thick plate made from 410 grade stainless steel is to be reduced to 34 mm in one pass in a…

A:

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

A:

Q: A 40 mm thick plate made from 410 grade stainless steel is to be reduced to 34 mm in one pass in a…

A:

Q: A solid piece of steel 60 mm in diameter and 80 mm height is reduced in height by 50 percent with…

A:

Q: 13mm diameter rod is to be reduced to 11mm diameter by drawing in a single pass at a speed of…

A:

Q: A 40 mm thick plate made from 410 grade stainless steel is to be reduced to 34 mm in one pass in a…

A:

Q: . A cylindrical billet that is 100 mm long and 50 mm in diameter is reduced by direct (forward)…

A:

Q: A cylindrical workpiece of 100mm diameter and 150mm in height (Fig. 1) is upset (open die forged) at…

A: The height of the cylinder is h1=150 mm. The diameter of the cylinder is d1=100 mm. The height of…

Q: Explain why friction is undesirable in metal forming operations.

A: Forming is a process in which material undergoes plastic deformation to get desired shape and size.

Q: A 200 mm wide and 42.0 mm thick plate made of low carbon steel is to be reduced in one pass in a…

A: Given: The width of the plate, b1 = 200 mm The thickness of plate initially, t1 = 42 mm The increase…

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

A:

Q: What is K-factor in sheet metal operation? Mention its value.

A:

Q: A sheet 300mm wide 25mm thick with two drives, each with a radius of 250mm it is passed through a…

A:

Q: A solid piece of steel 60 mm in diameter and 80 mm height is reduced in height by 50 percent with…

A:

Q: A rolling operation on a 250 mm wide, 8 mm thick, 1112 cold rolled steel takes place using hardened…

A: Since it is not mentioned how many parts in the question are to be solved, the first three subparts…

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 cylindrical billet that is 80 mm long and 32 mm diameter is reduced by backward extrusion to a 12…

A:

Q: Example 3: A hydraulic forging press is capable of exerting a maximum force 1,000,000 N. A…

A:

Q: What is K constant in sheet metal bending? How to calculate shear force and extrusions? Formulas?

A: When sheet metal bends, the bend allowance is given byLb=αR+ktWhere ,Lb=is the bend allowance α=bend…

Q: It is not possible to conduct rolling process without friction. Explain this statement

A: The friction force is the force that provides the torque required for the object to acquire the…

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: A solid piece of steel 60 mm in diameter and 80 mm height is reduced in height by 50 percent with…

A:

Q: A 10 mm thick plate is rolled to 7 mm thick in a rolling mill using 1000 mm diameter rigid rolls.…

A: Rolling Operation: It is one of the important operations in manufacturing. Rolling is a process…

Q: A metal strip is to be rolled from an initial wrought thickness of 3.5 mm to a final rolled…

A: First calculate the Projected length of the deformation zone in horizontal plane and is given by…

Q: A rolling operation on a 250 mm wide, 8 mm thick, 1112 cold rolled steel takes place using hardened…

A:

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…

Q: Estimate the roll force, F, and the torque for an AISI 1020 carbon-steel strip that is 200 mm wide,…

A: The draft attempted in this rolling operation is d=10mm-7mm   =3mm assuming coefficient of friction…

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.