EBK MANUFACTURING PROCESSES FOR ENGINEE
6th Edition
ISBN: 9780134425115
Author: Schmid
Publisher: YUZU
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Chapter 6, Problem 6.99P
To determine
The force required for forging.
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1. 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?
Calculate (1) die pressure distribution and (2) forging
force for plane strain forging (open die forging).
Assume yield strength of the material is Y, and yielding
criterion is von Mises.
ho
2Lo
h
Forged to
2L
xdx
L
'x+value
Note: Assume Zo Constant Plane strain
Die pressure distribution
h
L
L
Die pressure distribution
h
MATERIAL
L
dx
-(-1)
Friction Hill
Y
L
When 0;
=Y
P=Y' =
Calculate forging force
X
L
dF elemental
volume
Average pressure
A 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.
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
Ch. 6 - Prob. 6.11QCh. 6 - Prob. 6.12QCh. 6 - Prob. 6.13QCh. 6 - Prob. 6.14QCh. 6 - Prob. 6.15QCh. 6 - Prob. 6.16QCh. 6 - Prob. 6.17QCh. 6 - Prob. 6.18QCh. 6 - Prob. 6.19QCh. 6 - Prob. 6.20QCh. 6 - Prob. 6.21QCh. 6 - Prob. 6.22QCh. 6 - Prob. 6.23QCh. 6 - Prob. 6.24QCh. 6 - Prob. 6.25QCh. 6 - Prob. 6.26QCh. 6 - Prob. 6.27QCh. 6 - Prob. 6.28QCh. 6 - Prob. 6.29QCh. 6 - Prob. 6.30QCh. 6 - Prob. 6.31QCh. 6 - Prob. 6.32QCh. 6 - Prob. 6.33QCh. 6 - Prob. 6.34QCh. 6 - Prob. 6.35QCh. 6 - Prob. 6.36QCh. 6 - Prob. 6.37QCh. 6 - Prob. 6.38QCh. 6 - Prob. 6.39QCh. 6 - Prob. 6.40QCh. 6 - Prob. 6.41QCh. 6 - Prob. 6.42QCh. 6 - Prob. 6.43QCh. 6 - Prob. 6.44QCh. 6 - Prob. 6.45QCh. 6 - Prob. 6.46QCh. 6 - Prob. 6.47QCh. 6 - Prob. 6.48QCh. 6 - Prob. 6.49QCh. 6 - Prob. 6.50QCh. 6 - Prob. 6.51QCh. 6 - Prob. 6.52QCh. 6 - Prob. 6.53QCh. 6 - Prob. 6.54QCh. 6 - Prob. 6.55QCh. 6 - Prob. 6.56QCh. 6 - Prob. 6.57QCh. 6 - Prob. 6.58QCh. 6 - Prob. 6.59QCh. 6 - Prob. 6.60QCh. 6 - Prob. 6.61QCh. 6 - Prob. 6.62QCh. 6 - Prob. 6.63QCh. 6 - Prob. 6.64QCh. 6 - Prob. 6.65QCh. 6 - Prob. 6.66QCh. 6 - Prob. 6.67QCh. 6 - Prob. 6.68QCh. 6 - Prob. 6.69QCh. 6 - Prob. 6.70QCh. 6 - Prob. 6.71QCh. 6 - Prob. 6.72QCh. 6 - Prob. 6.73PCh. 6 - Prob. 6.74PCh. 6 - Prob. 6.75PCh. 6 - Prob. 6.76PCh. 6 - Prob. 6.77PCh. 6 - Prob. 6.78PCh. 6 - Prob. 6.79PCh. 6 - Prob. 6.80PCh. 6 - Prob. 6.81PCh. 6 - Prob. 6.82PCh. 6 - Prob. 6.83PCh. 6 - Prob. 6.84PCh. 6 - Prob. 6.85PCh. 6 - Prob. 6.86PCh. 6 - Prob. 6.87PCh. 6 - Prob. 6.88PCh. 6 - Prob. 6.89PCh. 6 - Prob. 6.90PCh. 6 - Prob. 6.91PCh. 6 - Prob. 6.92PCh. 6 - Prob. 6.93PCh. 6 - Prob. 6.94PCh. 6 - Prob. 6.95PCh. 6 - Prob. 6.96PCh. 6 - Prob. 6.97PCh. 6 - Prob. 6.98PCh. 6 - Prob. 6.99PCh. 6 - Prob. 6.100PCh. 6 - Prob. 6.101PCh. 6 - Prob. 6.102PCh. 6 - Prob. 6.103PCh. 6 - Prob. 6.104PCh. 6 - Prob. 6.105PCh. 6 - Prob. 6.106PCh. 6 - Prob. 6.107PCh. 6 - Prob. 6.108PCh. 6 - Prob. 6.109PCh. 6 - Prob. 6.110PCh. 6 - Prob. 6.111PCh. 6 - Prob. 6.112PCh. 6 - Prob. 6.113PCh. 6 - Prob. 6.114PCh. 6 - Prob. 6.115PCh. 6 - Prob. 6.116PCh. 6 - Prob. 6.117PCh. 6 - Prob. 6.118PCh. 6 - Prob. 6.119PCh. 6 - Prob. 6.120PCh. 6 - Prob. 6.121PCh. 6 - Prob. 6.122PCh. 6 - Prob. 6.123PCh. 6 - Prob. 6.124PCh. 6 - Prob. 6.125PCh. 6 - Prob. 6.126PCh. 6 - Prob. 6.127PCh. 6 - Prob. 6.128PCh. 6 - Prob. 6.129PCh. 6 - Prob. 6.130PCh. 6 - Prob. 6.131PCh. 6 - Prob. 6.132PCh. 6 - Prob. 6.133PCh. 6 - Prob. 6.134PCh. 6 - Prob. 6.135PCh. 6 - Prob. 6.136PCh. 6 - Prob. 6.137PCh. 6 - Prob. 6.138PCh. 6 - Prob. 6.139PCh. 6 - Prob. 6.140PCh. 6 - Prob. 6.142DCh. 6 - Prob. 6.143DCh. 6 - Prob. 6.144DCh. 6 - Prob. 6.145DCh. 6 - Prob. 6.146DCh. 6 - Prob. 6.147DCh. 6 - Prob. 6.149D
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- Question 7 A component is designed to be hot forged in an impression die. The projected area of the product is 5800 mm?. During the forging process flashing is formed so that the area including the flash will be 8900 mm?. 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. 7.1 7.2 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_forwardA cylindrical ingot with D0 = 50 mm and h0 = 40 mm is cold forged using an open die.The final height is 20 mm. The coefficient of form / friction between the die and the workpiece isconsider Kf = 1.10.The material from which the ingot is made has the following characteristics:K = 600 MPa and η = 0.12.Determine the force (F) on the operation:a) Force required at the moment of reaching the yield point (ℇ = 0.002)b) Force required when you have a height of h = 30 mmc) Force required when there is a final height of h = 20 mmd) Construct the graphs: Force vs Δh and effort vs Δharrow_forwardA compound die will be used to blank and punch a large rectangle (90x150mm blank dimensions) out of 6061ST aluminum alloy sheet stock 3.5 mm thick. The diameter of inside hole is 25 mm. The aluminum sheet metal has a tensile strength 310 MPa. Determine the minimum tonnage press (force) to perform the blanking and punching operation (1) assume that blanking and punching occur simultaneously and (2) assume that punching occurs first, then blanking, Take: Ac-0.06arrow_forward
- 2. 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_forwardA cylindrical billet of 60mm diameter is forged from 80mm height to 60mm at 1000 o C. The material has a constant flow stress of 80 MPa. Calculate the work done to deform. A 10kN drop hammer is used to complete the reduction in one blow. What will be the height of the fall?arrow_forward6.100 A 0.25-m-wide billet of 5052-O aluminum (K = 210 MPa, n = 0.13) is forged from a thickness of 30 mm to a thickness of 20 mm with a long die with a width of 75 mm. The coefficient of friction for the die/workpiece interface is 0.25. Calculate the maximum die pressure and required forging force.arrow_forward
- A 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_forwardManufacturer process A compound die will be used to blank and punch a large rectangle (90x150mm blank dimensions) out of 6061ST aluminum alloy sheet stock 3.5 mm thick. The diameter of inside hole is 25 mm. The aluminum sheet metal has a tensile strength = 310 MPa. Determine the minimum tonnage press (force) to perform the blanking and punching operation (1) assume that blanking and punching occur simultaneously and (2) assume that punching occurs first, then blanking. Take: Ac=0.06arrow_forwardThe height of the down sprue is 175 mm and its CS are at the base is 200 mm² The CS area of the horizontal runner is also 200 mm² Assuming no losses, indicate the correct choice for the time (second) required to fill a mould cavity of volume 106 mm³ (Use g=10 m/s^ 2 )arrow_forward
- A 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_forwardA solid piece of steel 60 mm in diameter and 80 mm height is reduced in height by 50 percent with the help of open die forging. The work material characteristics are represented by k = 350MPA and n = 0.16. If coefficient of friction is 0.1, find the %3D maximum forging force.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
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