A hot/cold rolling setup is shown right. The operation first hot rolls a 3/8” thick plate, 12” wide (w), of 6061 Aluminum, to an intermediate thickness, then finally through cold rolling, down to 1/4” thick plate. The friction factor μ is assumed to be constant at 0.15 for the hot roll, 0.12 for the cold rolling stage. The first set of rolls operate at 50 RPM. Also ignore any width increase during rolling. CW=13% or .13   What is the plate thickness (mm) prior to the last rolls, t1, if the last set of rollers perform cold work reduction listed below at .13 or 13% Note that 9.52 mm is equal to 3/8 of an inch

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Forming and Shaping

Metal forming is a category of metalworking process through which the material can be given the desired shape and size by subjecting it to plastic deformation, where the component undergoes bulk deformation process upon application of loads. Unlike the shearing and machining process, the material does not undergo up to a failure point as indicated in the stress-strain curve. Hence, the stresses induced during the forming process are greater than yield strength but less than the failure strength of the material. The process does not lead to the loss of material, so it can be said to be an economical process. During forming, the material is subjected to tensile forces, compressive forces, bending, and shearing loading conditions. The material should possess the property of ductility to undergo the forming process.