Concept explainers
The maximum contact force.
The height up to which the aluminum cylinder to be forged before the press stalls.
Answer to Problem 6.96P
The maximum contact force is
The required height of the cylinder is
Explanation of Solution
Given:
The power of motor is
The number of strokes per minute is
The stroke length of the crankshaft is
The initial diameter of the cylinder is
The initial height of the cylinder is
Formula used:
The expression for the initial radius is given as,
The expression for velocity is given as,
The expression for power is given as,
Here,
The expression for volume consistency of the cylinder is given as,
Here,
The expression for relation of force in terms of yield strength is given as,
Here,
Calculation:
The initial radius of the cylinder can be calculated as,
The velocity can be calculated as,
The force from the relation of power can be calculated as,
From volume consistency, relation between final radius and final height can be calculated as,
From the table 3.5, “Properties of various aluminum alloys at room temperature”, yield strength can be given as,
From equation (1) and (2)final radius of the cylinder can be calculated as,
On further solving,
Now from equation (2) height of the cylinder can be calculated as,
Conclusion:
Therefore, the maximum contact force is
Therefore, the required height of the cylinder is
Want to see more full solutions like this?
Chapter 6 Solutions
Manufacturing Processes for Engineering Materials (6th Edition)
- A 40 mm thick plate made from 410 grade stainless steel is to be reduced to 34 mm in one pass in a rolling operation. As the thickness is reduced, the plate widens by 3%. The entrance speed of the plate is 13 m/min and the roll radius is 310 mm with a rotational speed of 30 rpm. 5.1 Calculate the minimum coefficient of friction required, that will make the rolling operation possible. 5.2 Calculate the exit velocity of the plate. 5.3 Calculate the forward slip. 5.4 If the final width of the sheet is 200 mm, calculate the required roll force. 5.5 Explain what is roll flattening, its effects and how it can be reduced.arrow_forward1. A round wire made from 1020 carbon steel is being drawn from a diameter of 12.5 mm to 9.5 mm in a draw die of 10°. For a coefficient of friction of 0.15, calculate required drawing force. 2. How would the extrusion process be effected if the die angle is increased?arrow_forwardA strip (300x30 mm) is fed through a rolling mill with two powered rolls (each with radius of 300 mm) rotating at the speed of 60 rpm. The flow stress of work material is 90 MPa, and the coefficient of friction between rolls and work is 0.12. For a single rolling operation performed at the contact angle of 6.28°, calculate the followings:a) Work thickness after rolling (in mm)arrow_forward
- A 300mm thick slab is being cold rolled using roll of 600mm diameter.If the coefficient of friction is 0.08. Determine the maximum possible reduction.arrow_forwardQuestion 1 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.arrow_forward1. A component is designed to be hot forged in an impression die. The projected area of the product is 5800 mm2. During the forging process flashing is formed so that the area including the flash will be 8900 mm2. The part geometry is considered to be simple and the heated work material yields at 92 MPa. Calculate the maximum force required to perform the operation. 2. What are the advantages and disadvantages to forge a product through the open forging process, rather than to machine it from the same material?arrow_forward
- In a sheet metal forming press, the shape to be formed is hemispherical cup of radius 15 cm in 2mm thick mild steel sheet. The force required to deform sheet is 8 kN. The forming hammer should approach job from a distance of 30 cm. The production rate required is 240 components/hr. Calculate and suggest the following specifications of the various hydraulic components used: a. Hydraulic cylinder (bore & length); b. Pump pressure and flow rate; c. Electric motor HP considering 75% pump efficiency; d. Reservoir size; and e. Size of pump inlet and discharge tubing.arrow_forwardA 40 mm thick plate made from 410 grade stainless steel is to be reduced to 34 mm in one pass in a rolling operation. As the thickness is reduced, the plate widens by 3%. The entrance speed of the plate is 13 m/min and the roll radius is 310 mm with a rotational speed of 30 rpm. To do 5.1 If the final width of the sheet is 200 mm, calculate the required roll force. 5.2. Explain what is roll flattening, its effects and how it can be reduced.arrow_forwardA solid cylinder of diameter 100 mm and height 50 mm is forged between two frictionless flat dies to a height of 25 mm. What is the percentage change in diameter?arrow_forward
- An annealed 4340 steel strip of 300 mm width and 7 mm thickness is rolled to a thickness of 5 mm. The roll radius is 175 mm and rotates at 180 rpm. Calculate the roll force and the power required for the process.arrow_forwardA 300 mm thick slab is being cold rolled using roll of 600 mm diameter. If the coefficient of friction is 0.08, the maximum possible reduction is,arrow_forwardA piece with a height of 120 mm and a diameter of 75 mm can be increased to 80 mm in height by pile-forging.is reduced. The coefficient of friction between the workpiece and the mold is 0.13. Flow curve of the workpiece, 165It is defined by a strength coefficient of MPa and a hardening exponent of 0.24. force during operationCalculate at the moments given below and obtain the force-workpiece height graph(1) as soon as it reaches the yield point (yield strain = 0.002),(2) height h = 115 mm,(3) height h = 110 mm,(4) height h = 105mm,(5) height h = 100mm,(6) height h=95mm,(7) height h = 90 mm,(8) height h = 85mm,(9) height h = 80 mm,arrow_forward
- Elements Of ElectromagneticsMechanical EngineeringISBN:9780190698614Author:Sadiku, Matthew N. O.Publisher:Oxford University PressMechanics of Materials (10th Edition)Mechanical EngineeringISBN:9780134319650Author:Russell C. HibbelerPublisher:PEARSONThermodynamics: An Engineering ApproachMechanical EngineeringISBN:9781259822674Author:Yunus A. Cengel Dr., Michael A. BolesPublisher:McGraw-Hill Education
- Control Systems EngineeringMechanical EngineeringISBN:9781118170519Author:Norman S. NisePublisher:WILEYMechanics of Materials (MindTap Course List)Mechanical EngineeringISBN:9781337093347Author:Barry J. Goodno, James M. GerePublisher:Cengage LearningEngineering Mechanics: StaticsMechanical EngineeringISBN:9781118807330Author:James L. Meriam, L. G. Kraige, J. N. BoltonPublisher:WILEY