EBK MANUFACTURING PROCESSES FOR ENGINEE
6th Edition
ISBN: 9780134425115
Author: Schmid
Publisher: YUZU
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Chapter 6, Problem 6.105P
To determine
Thestresses are tensile or compressive and principal stresses can be equal in magnitude or not.
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A 4-in-thick aluminum slab is 10 in wide and 100 in long. It is reduced in one pass in a two-high rolling mill to a thickness = 3.5 in. The roll rotates at a speed = 12 rev/min and has a radius = 20 in. The aluminum has a strength coefficient = 25,000 lb/in2 and a strain hardening exponent = 0.20. Determine the (a) roll force, (b) roll torque, and (c) power required to accomplish this operation, d) Estimate the GHG emission in an hour for the rolling operation.
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Chapter 6 Solutions
EBK MANUFACTURING PROCESSES FOR ENGINEE
Ch. 6 - Prob. 6.1QCh. 6 - Prob. 6.2QCh. 6 - Prob. 6.3QCh. 6 - Prob. 6.4QCh. 6 - Prob. 6.5QCh. 6 - Prob. 6.6QCh. 6 - Prob. 6.7QCh. 6 - Prob. 6.8QCh. 6 - Prob. 6.9QCh. 6 - Prob. 6.10Q
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- In open-die forging, a disc of diameter 200 mm and height 60 mm is compressed without any barreling effect. The final diameter of the disc is 400 mm. The true strain isarrow_forwardA 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_forwardWire is drawn through a draw die with entrance angle a= 17°. Starting diameter is 3.0 mm and final diameter = 2.4 mm. The coefficient of friction at the work-die interface = 0.08. The metal has a strength coefficient K = 205 MPa and a strain-hardening exponent n = draw force in this operation. Why are multiple passes usually required to achieve the desired reduction? (Hint: Observe the draw stress value found in this question) 0.20. Determine the draw stress and Lubricant box Initial wire stock (in coil form) Multiple pass/draft drawing Draw die V2, F V3, F shown in figure. Capstan drum (holds multiple loops of wire) (1) (2) (3)arrow_forward
- A long, copper strip, 500 mm wide, 3 mm thick, was found to have 450 MPa yield stress. The strip is required to be rolled in order to reduce its thickness. In the rolling process, the width remains practically unchanged while the rolls apply pressure in the thickness direction. An additional tension of 150 kN is applied in the longitudinal direction to assist the forming process. Ignoring the change in the width and any friction effects, determine what roll pressure would just cause deformation: according to the Von Mises yield criterion. according to the Tresca yield criterion. Material properties in the elastic range: E=75 GPa, v=0.4. (a) (b)arrow_forwardDetermine the minimum tonnage press to perform the blanking and punching operation in Problem 8. 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 blankingarrow_forwardA spool of copper wire has a starting diameter of 2.5 mm. It is drawn through a die with an opening that is 2.1 mm. The entrance angle of the die = 18°. Coefficient of friction at the work die interface is 0.08. The pure copper has a strength coefficient = 300 MPa and a strain hardening coefficient = 0.50. The operation is performed at room temperature. Determine (a) area reduction, (b) draw stress, and (c) draw force required for the operation.arrow_forward
- A spool of wire has a starting diameter of 2.5 mm. It is drawn through a die with an opening that is 2.1 mm at a speed of 0.3 m/s. The worked metal has a strength coefficient of 450 MPa and a strain-hardening coefficient of 0.26. Assume the drawing is performed at room temperature and that the frictional and redundant work together constitute 35% of the ideal work of deformation. Calculate the power required to carry out the operationarrow_forwardA 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. The coefficient of friction at the die-work interface is 0.25. The yield strength of the work material is 285 MPa, and its flow curve is defined by a strength coefficient of 600 MPa and a strain-hardening exponent of 0.12. Calculate the strain at yield point.arrow_forwardA 3in long and 1in diameter billet is extruded in a direct extrusion operation with an rx = 4.0. The extrusion has a cross section. The angle of the die (half angle) is 90o. The work metal has a resistance coefficient of 60ksi and a strain hardening exponent of 0.18. Use Johnston's formula with a = 0.8 and b = 1.5 to estimate the extrusion stress. Determine the pressure applied to the end of the billet when the piston moves forward.arrow_forward
- A copper strip of 200 mm width and 300 mm thickness is to be rolled to a thickness of 295 mm The roll of radius 300 mm rotates at 100 rpm. The average shear strength of the work material is 180 MPa. Calculate the roll strip contact length and the roll force .arrow_forwardA steel billet with a rectangular cross section is being forged using a die with a width of 84.5 mm. The billet has an original thickness of 46.0 mm and a width of 273 mm. The billet is upset to a thickness of 28.0 mm and the coefficient of friction for the workpiece-die interface is 0.234. Take the strength coefficient (K) as 526 MPa and the strain-hardening exponent (n) as 0.225. a) Determine the maximum die pressure (do not use average pressure formula). Expected answer: 1050 MPa b) Determine the required forging force (use average pressure). Expected answer: 16200000 Narrow_forwardBriefly explain various methods available for breakdown passes in rolling. Explain their applications.arrow_forward
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