EBK MANUFACTURING ENGINEERING & TECHNOL
7th Edition
ISBN: 8220100793431
Author: KALPAKJIAN
Publisher: PEARSON
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Chapter 15, Problem 36QLP
Why is lubrication detrimental in extrusion with a porthole die?
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What are the advantages and limitations of extrusion process?
A billet 100 mm long and 30 mm in diameter is to be extruded in a direct
extrusion operation with extrusion ratio r, = 3.5. The extrudate has a round cross
section. The die angle (half angle) = 60°. The work metal has a strength
coefficient = 720 MPa, and strain hardening exponent = 0.17. Use the Johnson
formula with a = 0.8 andb= 1.2 to estimate extrusion strain. Determine the
following:
1. Diameter of the extrudate =
mm
2. Butt volume =
mm3
3. Actual extrudate length =
mm
4. The pressure applied to perform the extrusion process =
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5. Ram force =
N.
A upset forging operation is performed in an open die. The initial size of the workpart is: Do = 63 mm, and ho = 100 mm. The part is upset to a diameter = 70 mm. The work metal has a flow curve with strength coefficient = 600 MPa and strain hardening exponent= 0.22. Coefficient of friction at the die-work interface = 0.40. Determine (a) final height of the part, and (b) maximum force in the operation
Chapter 15 Solutions
EBK MANUFACTURING ENGINEERING & TECHNOL
Ch. 15 - How does extrusion differ from rolling and...Ch. 15 - Explain the difference between extrusion and...Ch. 15 - What is a spider die? What is it used for?Ch. 15 - Why are wires sometimes drawn in bundles?Ch. 15 - What is a dead-metal zone?Ch. 15 - Define the terms (a) cladding, (b) dummy block,...Ch. 15 - Why is glass a good lubricant in hot extrusion?Ch. 15 - What types of defects may occur in (a) extrusion...Ch. 15 - Describe the difference between direct and reverse...Ch. 15 - What is land? What is its function in a die?
Ch. 15 - How are tubes extruded? Can they also be drawn?...Ch. 15 - Prob. 12RQCh. 15 - What is the difference between piping and...Ch. 15 - What is impact extrusion?Ch. 15 - What is the pipe defect in extrusion?Ch. 15 - List the similarities and differences between...Ch. 15 - Explain why extrusion is a batch, or...Ch. 15 - The extrusion ratio, die geometry, extrusion...Ch. 15 - Explain why cold extrusion is an important...Ch. 15 - What is the function of a stripper plate in impact...Ch. 15 - Explain the different ways by which changing the...Ch. 15 - Glass is a good lubricant in hot extrusion. Would...Ch. 15 - How would you go about avoiding center-cracking...Ch. 15 - Table 15.1 gives temperature ranges for extruding...Ch. 15 - Will the force in direct extrusion vary as the...Ch. 15 - Comment on the significance of metal flow patterns...Ch. 15 - In which applications could you use the type of...Ch. 15 - What is the purpose of the land in a drawing die?...Ch. 15 - Can spur gears be made by (a) drawing and (b)...Ch. 15 - How would you prepare the end of a wire in order...Ch. 15 - What is the purpose of a dummy block in extrusion?...Ch. 15 - Describe your observations concerning Fig. 15.9.Ch. 15 - Occasionally, steel wire drawing will take place...Ch. 15 - Explain the advantages of bundle drawing.Ch. 15 - Under what circumstances would backward extrusion...Ch. 15 - Why is lubrication detrimental in extrusion with a...Ch. 15 - In hydrostatic extrusion, complex seals are used...Ch. 15 - Describe the purpose of a container liner in...Ch. 15 - Estimate the force required in extruding 7030...Ch. 15 - Assuming an ideal drawing process, what is the...Ch. 15 - Prob. 41QTPCh. 15 - Calculate the extrusion force for a round billet...Ch. 15 - Prob. 43QTPCh. 15 - A round wire made of a perfectly plastic material...Ch. 15 - Assume that the summary to this chapter is...Ch. 15 - Prob. 47SDPCh. 15 - Figure 15.2 shows examples of discrete parts that...Ch. 15 - The parts shown in Fig. 15.2 are economically...Ch. 15 - Survey the technical literature, and explain how...Ch. 15 - Prob. 51SDPCh. 15 - List the processes that are suitable for producing...
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- A cylindrical billet that is 100 mm long and 50 mm in diameter is reduced by indirect (backward) extrusion to a 20 mm diameter. The die angle is 90°. In the Johnson equation, a = 0.8 and b = 1.4. In the flow curve for the work metal, the strength coefficient = 800 MPa and strain hardening exponent = 0.13. Determine (a) extrusion ratio, (b) true strain (homogeneous deformation), (c) extrusion strain, (d) ram pressure, and (e) ram force Please answer d and e (a) Calculate the extrusion ratio. r=6.25 (b) Calculate the true strain. εtrue=1.8333 (c) Calculate the extrusion strain by using Johnson's equation. εext =3.366arrow_forwardA cylindrical billet that is 100 mm long and 50 mm in diameter is reduced by indirect (backward) extrusion to a 20 mm diameter. The die angle is 90°. In the Johnson equation, a = 0.8 and b = 1.4. In the flow curve for the work metal, the strength coefficient = 800 MPa and strain hardening exponent = 0.13. Determine (a) extrusion ratio, (b) true strain (homogeneous deformation), (c) extrusion strain, (d) ram pressure, and (e) ram forcearrow_forwardExplain the function of a dummy block in Direct Extrusion Processarrow_forward
- A billet 75mmlong and 25mmin diameter is to be extruded in a direct extrusion operation with extrusion ratio rx = 4.0. The extrudate has a round cross section. The die angle (half angle) = 90° The work metal has a strength coefficient = 415 MPa, and strainhardening exponent = 0.18. Use the Johnson formula with a = 0.8 and b = 1.5 to estimate extrusion strain. Determine the pressure applied to the end of the billet as the ram moves forwardarrow_forwardWhat are the advantages of a counterblow or impact forging machine? What are some of the properties desired in forging dies?arrow_forwardIllustrate the advantages of direct extrusion on indirect extrusion?arrow_forward
- During a direct extrusion process for a billet with 5 in long and diameter 2.5 in to 1.6 in. For the work metal, strength coefficient is 75000 Ib/in, and strain hardening exponent is 0.4, also the die angle of extrusion is 90. In Johnson extrusion strain equation a = 0.8, and b= 1.5. Determine: (a) extrusion ratio (b) true strain (c) extrusion strain, and (d) ram pressure at length 5, 4.2, 2.3,1.5,and 0 in.arrow_forwardExample 10.3 A cylindrical billet of 40 mm diameter and 100 mm length is reduced by indirect (backward) extrusion to a 15 mm diameter using Flat dies. If the Johnson equation has a = 0.8 and b = 1.5 and the flow curve for the work metal has K = 750 MPa and n = 0.15, determine : (i) Extrusion rations (ii) True strain (homogencous deformation) (iii) Extrusion strain (iv) Ram forcearrow_forwardfollowing figure. What is the liners function in reverse extrusion? Container A- Describe the purpose of a container liner in direct extrusion, as shown in the Container liner - Pressing stem Billet Die. Die backer, Dummy block B- Estimate the force required in extruding 70-30 brass at 700 C if the billet diameter is 200 mm and the extrusion ratio is 30. Use the following figure. Extrusion 800 1000 1200 1400 600 400 80 Stainless steel Beryllium 400 60 70-30 Brass Cold-rolled Copper 200 steel 20 1100 Aluminum 2500 2000 1500 1000 Temperature ("F) Chromit Molybdenum Extrusion constant, k (10° psi) MPaarrow_forward
- A billet 100 mm long and 40 mm diameter is to be extruded in a direct extrusion with final diameter of product 32 mm. The semi die angle is 60°. The work metal has a strength coefficient 500 Map, and strain hardening 0.2 use the Johnson formula with a=0.8 and b=1.45 to estimate the extrusion strain. Determine the pressure applied to the end of the billet as the ram moves forward.arrow_forwardA cylindrical billet that is 80 mm long and 32 mm diameter is reduced by backward extrusion to a 12 mm diameter. Half die angle is 90°. If the Johnson equation has a= 0.8 and b= 1.2 , and the flow curve for the work material has strength coefficient is 500 MPa, and strain hardening exponent is 0.8, Determine (a) extrusion ration, (b) true strain, (c) extrusion strain, (d) ram pressure, and (e) ram force.arrow_forwardQ#3:(b) Explain the differences between Forward Extrusion and Reverse Extrusion processesarrow_forward
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