EBK MANUFACTURING PROCESSES FOR ENGINEE
6th Edition
ISBN: 9780134425115
Author: Schmid
Publisher: YUZU
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Chapter 6, Problem 6.17Q
To determine
The cogging operation can be implemented to produce thin sheets.
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4) Make a summary of the types of defects found in sheet-metal forming processes,
and include brief comments on the reason(s) for each defect.
* A cylindrical workpiece made of 1100-0 Aluminum that is 18 in high and 16 in in diameter and is to
be reduced in height by 25% by open-die forging. Let the coefficient of friction be 0.15. K=20
mpa,n=0.35,
Calculate the forging force.
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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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- Forging processes may be characterized by die work limitation. This categorization yields three basic types.arrow_forwardExplain what you know about crystallographic anisotropy, which has an important place in sheet metal forming operations, with the help of shapes and formulations.arrow_forwardQ#4: (b) Explain the disadvantages of Tube Drawing process in which mandrel is not used.arrow_forward
- 1. A cylindrical billet that is 100 mm long and 50 mm in diameter is reduced by direct (forward) extrusion to a 20 mm diameter. The die angle is 90°. the flow curve for the work metal has a strength coefficient of 800 MPa. Determine (a) extrusion ratio, (b) true strain (homogeneous deformation), (c) ram pressure, and (e) ram force.arrow_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 d) ram pressure, and (e) ram forcearrow_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_forward
- 5. Determine the maximum possible reduction for cold rolling a 300mm thick slab when μ = 0.08, and roll diameter is 600mm. What is the maximum reduction on the same mill for hot rolling when μ = 0.05. 6. Explain different types of defects which are possible in the welding process.arrow_forwardYou have been asked to work on some design problems and technically support the team working on extrusion and forging operations: 1) The team are extruding a billet that is 80 mm long with diameter of 40 mm is directly to a diameter of 20 mm. The extrusion die has a die angle of 75°, see Figure 1. For the work metal, K = 600 MPa and n = 0.25. In the Johnson extrusion strain equation, a = 0.8 and b = 1.4. Remaining billet length 75 Ram pressure, p D. Dr Figure 1: Extrusion process. Determine the following design parameters: (a) Extrusion ratio. (b) True strain (homogeneous deformation). (c) Extrusion strain. (d) Ram pressure at L= 80, 40, and 10 mm. (e) Draw the relationship between the ram pressure and billet length and discuss the results. What are your recommendations to dccrcase the required ram pressure?arrow_forward1) A cup-drawing operation is performed in which: The cup's inside diameter = 75 mm and its height = 50 mm. %3D Stock thickness = 3.0 mm. %3D Punch and die radii = 4 mm. Tensile strength = 400 MPa for this sheet metal. %3D (a) Find the required starting blank size (b) Is this drawing operation feasible? (c) Determine the drawing force, and (d) Determine the blank-holder force.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 e) Size of pump inlet and discharge tubingarrow_forward2. A rectangular prism with dimension of height, ho, length, 2Lo, width, Zo is forged to a final dimension of height, h, length, 2L, width, Zo, by open die forging under plane-strain condition. If the coefficient of friction between the die and workpiece is µ (assume sliding friction in the die workpiece interface) and the yield strength of the material is Y, please prove (1) The die pressure at the end of stroke is: P= 2 √3 2μ Yeh -(L-x) where x is the distance from center of the workpiece. (2) If a rectangular specimen made of annealed Steel (σ = 25,000ε 0.25 psi) needs to be forged by the process above from 2L0 = 6 inch, ho = 4 inch, Zo =1 inch with flat dies to a height of h = 2 inch at room temperature. Assuming that the coefficient of friction is 0.2, calculate the average pressure and force required at the end of the stroke.arrow_forwardExplain why friction is undesirable in metal forming operations.arrow_forward
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