An open die forging operation is performed to produce a steel cylinder with a diameter o 9.7mm and a height of 1.7mm. The strength coefficient for this steel is 500MPA, and th strain hardening exponent is 0.25. Coefficient of friction at the die-work interface is 0.12 The initial stock of raw material has a diameter of 5mm. (a) What height/length of stock is needed to provide sufficient volume of material for thi forging operation? (b) Compute the maximum force that the punch must apply to form the head in this open die operation.

Q: c) A flat rolling operation is being carried out where the roll radius is 200 mm and the roll…

A: A rolling force is applied by rollers to the workpiece so as to reduce its thickness Maximum…

Q: Figure 1. shows the rolling operation. Determine the position bn. of the neutral point? Neglect…

A:

Q: Estimate the power for annealed low carbon steel strip 200 mm wide and 10 mm thick, rolled to a…

A: Rolling is a metal forming process in which a material is plastically deformed by passing it between…

Q: To what thickness can a solid cylinder of 6061-0 aluminium, that is 20 mm in diameter and 50 mm…

A:

Q: ◆ A billet 75 mm long and 25 mm in diameter is to be extruded in a direct extrusion operation with…

A: Step 1:Step 2:

Q: A hot rolling operation is being carried out on 250 mm wide and 25mm thick low carbon steel…

A: Calculate the final thickness. hf=1-0.2ho   =0.8×25   =20 mm Calculate the strain. Strain ε=lnhohf…

Q: A round disk of 200-mm diameter is blanked from a strip of 3.0-mm, half-hard cold-rolled steel whose…

A: Given data: d=200 mmt=3 mmτ=300 MPaAc=0.075 Need to determine the punch, die diameters and blanking…

Q: A compression test is performed on a 2” diameter by 5” long bar of an unknown metal.  At the end of…

A: Given:d1=2 inl1=5 inl2=3.5 inK=250 MPan=0.4a)Volume before compression=volume after compression…

Q: Estimate the power for annealed low carbon steel strip 200 mm wide and 10 mm thick, rolled to a…

A: Given w=200mmti=10mmtf=6mmμ=0.1n=0.26σ=530 MPa

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.