Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 5, Problem 27QLP
The cost of mill products of metals increases with decreasing thickness and section size. Explain why.
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There are three temperature ranges in metal forming, cold working, warm working andhot working. Distinguish cold working from warm working including their advantages anddisadvantages
1 What is the difference between open-die and closed-die forging? Give an example of a metal product produced by each process.
A compound die will be used to blank and
punch a large washer out of 6061ST
aluminum alloy sheet stock 3.50 mm
thick. The outside diameter of the washer
is 50.0 mm and the inside diameter is
15.0 mm. if The aluminum sheet metal
has a tensile strength = 310 MPa, a
strength coefficient of 350 MPa, and a
strain-hardening exponent of 0.12. (a)
Assume that blanking and punching occur
simultaneously. (b) Assume the punches
are staggered so that punching occurs
first, then blanking. Determine (1) the
punch and die sizes for the blanking
operation, and (2) the punch and die sizes
for the punching operation.(3) the
minimum tonnage press to perform the
blanking and punching operation
Chapter 5 Solutions
Manufacturing Engineering & Technology
Ch. 5 - What are the major categories of ferrous alloys?Ch. 5 - Prob. 2RQCh. 5 - List the basic raw materials used in making iron...Ch. 5 - List the types of furnaces commonly used in...Ch. 5 - List and explain the characteristics of the types...Ch. 5 - Prob. 6RQCh. 5 - What is continuous casting? What advantages does...Ch. 5 - What is the role of a tundish in continuous...Ch. 5 - Prob. 9RQCh. 5 - What are trace elements?
Ch. 5 - What are the percentage carbon contents of...Ch. 5 - Prob. 12RQCh. 5 - Prob. 13RQCh. 5 - Prob. 14RQCh. 5 - Prob. 15RQCh. 5 - What is high-speed steel?Ch. 5 - Prob. 17RQCh. 5 - Prob. 18RQCh. 5 - Prob. 19RQCh. 5 - What effect does carbon content have on mechanical...Ch. 5 - Identify several different products that are made...Ch. 5 - Professional cooks generally- prefer carbon-steel...Ch. 5 - Prob. 23QLPCh. 5 - Explain why continuous casting has been such an...Ch. 5 - Describe applications in which you would not want...Ch. 5 - Explain what would happen if the speed of the...Ch. 5 - The cost of mill products of metals increases with...Ch. 5 - Describe your observations regarding the...Ch. 5 - Prob. 29QLPCh. 5 - Prob. 30QLPCh. 5 - In Table 5.9, D2 steel is listed as a more common...Ch. 5 - List the common impurities in steel. Which of...Ch. 5 - Explain the purpose of the oil shown at the top...Ch. 5 - Recent research has identified mold-surface...Ch. 5 - Prob. 35QLPCh. 5 - List and explain the advantages and disadvantages...Ch. 5 - Conduct an Internet search and determine the...Ch. 5 - Refer to the available literature, and estimate...Ch. 5 - Some soft drinks are now available in steel cans...Ch. 5 - Using strength and density data, determine the...Ch. 5 - The endurance limit (fatigue life) of steel is...Ch. 5 - Using the data given in Table 5.4, obtain the...Ch. 5 - Based on the information given in Section 5.5.1,...Ch. 5 - Assume that you are in charge of public relations...Ch. 5 - Assume that you are in competition with the steel...Ch. 5 - In the past, waterfowl hunters used lead shot in...Ch. 5 - Aluminum is being used as a substitute material...Ch. 5 - In the 1940s (the Second World War), the Yamato...Ch. 5 - Search the technical literature, and add more...Ch. 5 - Referring to Fig. 5.4a, note that the mold has...
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- Explain what you know about crystallographic anisotropy, which has an important place in sheet metal forming operations, with the help of shapes and formulations.arrow_forwardQ3 Give the reason for 10 of the following. - 1- The use of lubricant in wire drawing die. 2- The uses of tungsten carbide for the manufacturing of die tool. 3- The increase of Mo/Si ratio during the production of white cast iron. 4- The addition of Al to copper alloys. 5- Aluminum is a better overall conductor than Copper for long distance electric transformation. 6- The addition of cryolite in smelting electrical furnace due to the production of aluminum. 7- The addition of Magnesium and Cerium during the production of Ductile cast iron. 8- The addition of 13% Cr to steel in corrosive environment. 9- The increase of hardness for chips due to the cutting process. 10- The brittle fracture of steel at low temperature lower than -4 C. 11- The heating of metal after the rolling process.arrow_forwardA 10 mm thick plate is rolled to 7 mm thick in a rolling mill using 1000 mm diameter rigid rolls. The neutral point is located at an angle of 0.3 times the bite angle from the exit. What will be the thickness of the plate at the neutral point.arrow_forward
- Forging processes may be characterized by die work limitation. This categorization yields three basic types.arrow_forwardThere are two common manufacturing processes that create long metal parts with a constant cross-section. With the aid of diagrams, explain these two processes and identify the similarities and differences between them.arrow_forwarda) The mechanism that causes an increase in the strength of the material during cold forming is called ....................b) Increasing deformation rate during hot formingThe strength of the .................. causes.c) In order not to increase .............. stress caused by friction in plastic forming processes ........... ... should be done.arrow_forward
- 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 d) ram pressure, and (e) ram forcearrow_forwardA stainless steel part is blanked from a larger sheet (0.5m wide, 1.0m long, 0.004m thick). Determine the tonnage (force) requirement for the blanking operation if the material shear strength is 600 MPa.arrow_forwardAn austenitic stainless steel plate with a width of 100 mm, a length of 150 mm and a thickness of 50 mm is to be hot forged in a hydraulic press so that the width remains constant. If it is to be reduced in one step to a thickness of 40 mm, calculatea) the actual load that needs to be applied at the end of the forging, as well as b) the corresponding deformation energy. In previous plane strain compression tests, it was found that the material exhibits an average plane strain yield stress of 80 MPa at the forging temperature. Assume that the efficiency of the process is 0.6 Answer: Pfr= 2.5 MN ; WTr= 25 kJarrow_forward
- Give short Definition about:! Give short Definition about 1. Rolling: 2. Extrusion: 3. Strength: 4. Elasticity: 5. Plasticity:arrow_forwardCircles of a metal are being punched that will be later stamped into coins. The metal has a shear strength of 32,575 psi. The sheets are 2.1 mm thick. The coin blanks are to be 16.5 mm in diameter. If sheet of metal is expected to produce 50 coin blanks, how much force is required to punch the sheets?arrow_forward27(A). Explain process which uses the application of force to give shape to metal and also explain its types used in the industry. List four applications related to process.arrow_forward
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