EBK MANUFACTURING ENGINEERING & TECHNOL
7th Edition
ISBN: 9780100793439
Author: KALPAKJIAN
Publisher: YUZU
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Chapter 14, Problem 34QTP
Using Eq. (14.2), estimate the forging force for the workpiece in Problem 14.33, assuming that it is a complex forging and that the projected area of the flash is 30% greater than the projected area of the forged workpiece.
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Explain the basic operation of closed-die forging. Use sketches to assist the explanation.
6.100 A 0.25-m-wide billet of 5052-O aluminum
(K = 210 MPa, n = 0.13) is forged from a thickness
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a width of 75 mm. The coefficient of friction for the
die/workpiece interface is 0.25. Calculate the maximum
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A solid, cylindrical workpiece made of 5052-O aluminum that is 87 mm high and 65.878 mm radius and is to be reduced in height by 30% using forging. The coefficient of friction is 0.168. 5052-O yield stress is 98.21 MPa, strain hardening exponent is 0.128 , and strength coefficient is 193.74 MPa.
Determine the forging force (MN) at the end of the stroke when the height has been reduced by 30%.
Chapter 14 Solutions
EBK MANUFACTURING ENGINEERING & TECHNOL
Ch. 14 - What is the difference between cold, warm, and hot...Ch. 14 - Explain the difference between open-die and...Ch. 14 - Explain the difference between fullering, edging,...Ch. 14 - What is flash? What is its function?Ch. 14 - Why is the intermediate shape of a part important...Ch. 14 - Describe the features of a typical forging die.Ch. 14 - Explain what is meant by load limited, energy...Ch. 14 - What type of parts can be produced by rotary...Ch. 14 - Why is hubbing an attractive alternative to...Ch. 14 - What is the difference between piercing and...
Ch. 14 - What is a hammer? What are the different kinds of...Ch. 14 - Why is there barreling in upsetting?Ch. 14 - What are the advantages and disadvantages of...Ch. 14 - Why are draft angles required in forging dies?Ch. 14 - Is a mandrel needed in swaging?Ch. 14 - Describe and explain the factors that influence...Ch. 14 - How can you tell whether a certain part is forged...Ch. 14 - Identify casting design rules, described in...Ch. 14 - Describe the factors involved in precision...Ch. 14 - Why is control of the volume of the blank...Ch. 14 - Why are there so many types of forging machines...Ch. 14 - What are the advantages and limitations of cogging...Ch. 14 - What are the advantages and limitations of using...Ch. 14 - Review Fig. 14.6e and explain why internal draft...Ch. 14 - Comment on your observations regarding the...Ch. 14 - Describe your observations concerning the control...Ch. 14 - Prob. 27QLPCh. 14 - Describe the difficulties involved in defining the...Ch. 14 - Describe the advantages of servo presses for...Ch. 14 - List the general recommendations you would make...Ch. 14 - Which would you recommend, (a) hot forging and...Ch. 14 - Take two solid, cylindrical specimens of equal...Ch. 14 - Calculate the room-temperature forging force for a...Ch. 14 - Using Eq. (14.2), estimate the forging force for...Ch. 14 - To what thickness can a solid cylinder of 1020...Ch. 14 - In Example 14.1, calculate the forging force,...Ch. 14 - Using Eq. (14.1), make a plot of the forging...Ch. 14 - How would you go about estimating the punch force...Ch. 14 - A mechanical press is powered by a 30-hp motor and...Ch. 14 - A solid cylindrical specimen, made of a perfectly...Ch. 14 - Devise an experimental method whereby you can...Ch. 14 - Assume that you represent the forging industry and...Ch. 14 - Figure P14.44 shows a round impression-die forging...Ch. 14 - Prob. 45SDPCh. 14 - Prob. 46SDPCh. 14 - Review the sequence of operations in the...Ch. 14 - Prob. 48SDPCh. 14 - Discuss the possible environmental concerns...Ch. 14 - List the advantages and disadvantages in using a...
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- Describe with the aid of a neat sketches two forging processes and briefly discuss their relative merits and limitations:arrow_forwardA 300 mm thick slab is being cold rolled using roll of 600 mm diameter. If the coefficient of friction is 0.08, the maximum possible reduction is,arrow_forwardA solid cylindrical slug made of 304 stainless steel is 150 mm in diameter and 100 mm high. It is reduced in height by 50% at room temperature by opendie forging with flat dies. Assuming that the coefficient of friction is 0.2 and the flow stress of this material is 1000 MPa, calculate the forging force at the end of the stroke. Manufacturing processesarrow_forward
- Answer this pleasearrow_forwardQuestion 6 6.1 A round wire made from 1020 carbon steel is being drawn from a diameter of 12.5 mm to 9.5 mm in a draw die of 10°. For a coefficient of friction of 0.15, calculate required drawing force. 6.2 How would the extrusion process be effected if the die angle is increased?arrow_forwardThe figure below shows a symmetric plane-strain upsetting process. The process may also be thought of as a form of side extrusion. Observations show that the deformation is confined to two shear planes, each one being analogous to that seen in plane-strain cutting. You may assume that there is no friction between the work material and the tool/die walls; the uniaxial yield strength of the material is σy and is independent of strain rate and temperature, and the material behaves as a rigid plastic solid. a) Calculate the pressure (p) required for the upsetting process in terms of σy. b) If friction existed at the die walls and the frictional work (energy) dissipation was 30% of the energy required for shape change alone (part (a) above), then what would be the pressure (p)?arrow_forward
- Nonearrow_forwardA 40 mm thick plate made from 410 grade stainless steel is to be reduced to 34 mm in one pass in a rolling operation. As the thickness is reduced, the plate widens by 3%. The entrance speed of the plate is 13 m/min and the roll radius is 310 mm with a rotational speed of 30 rpm. 5.1 Calculate the minimum coefficient of friction required, that will make the rolling operation possible. 5.2 Calculate the exit velocity of the plate. 5.3 Calculate the forward slip. 5.4 If the final width of the sheet is 200 mm, calculate the required roll force. 5.5 Explain what is roll flattening, its effects and how it can be reduced.arrow_forwardPlease answer all partsarrow_forward
- A upset forging operation is performed in an open die. The initial size of the workpart is: Do = 63 mm, and ho = 100 mm. The part is upset to a diameter = 70 mm. The work metal has a flow curve with strength coefficient = 600 MPa and strain hardening exponent= 0.22. Coefficient of friction at the die-work interface = 0.40. Determine (a) final height of the part, and (b) maximum force in the operation.arrow_forwardA small connecting rod is forged from AISI 1015 steel at 1200oC. Calculate the forging force in a mechanical press at a speed of 200 mm / s when the die comes into contact with the part. The volume of the connecting rod is estimated to be 28680 mm3, and 20% of the starting material is expected to burn off as flash (flash). In the final form the projected area is 3500 mm2 without flash. The width of the flash is 7.6mm around 300mm in circumference.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_forward
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