Degarmo's Materials And Processes In Manufacturing
13th Edition
ISBN: 9781119492825
Author: Black, J. Temple, Kohser, Ronald A., Author.
Publisher: Wiley,
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Chapter 17, Problem 4P
To determine
The benefits of spark plug threads formed by the cold rolling.
The assets and liabilities of the cold rolling of threads compared to thread formation by conventional machining.
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Estimate the power for annealed low carbon steel strip 200 mm wide and 10 mm thick, rolled to a thickness of 6 mm. The roll radius is 200 mm, and the roll rotates at 200 rev/min; use coefficient of friction at the die-work interface (p)=0.1. A low carbon steel such as AISI 1020 has K (strength coefficient) = 530 MPa and n ( strain hardening exponent) =0.26a)1059 kWb)950 kWc)1183 kWd)875 kW
The 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)?
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 17 Solutions
Degarmo's Materials And Processes In Manufacturing
Ch. 17 - What is plasticity?Ch. 17 - What are some of the general assets of the...Ch. 17 - Why might large production quantities be necessary...Ch. 17 - What types of deformation may occur in forming...Ch. 17 - What is an independent variable in a...Ch. 17 - What are some considerations regarding selection...Ch. 17 - What is the significance of tool and die geometry...Ch. 17 - Why is lubrication often a major concern in metal...Ch. 17 - What are some of the secondary effects that may...Ch. 17 - Prob. 10RQ
Ch. 17 - Why is it important to be able to predict the...Ch. 17 - Prob. 12RQCh. 17 - Prob. 13RQCh. 17 - Prob. 14RQCh. 17 - Prob. 15RQCh. 17 - Prob. 16RQCh. 17 - Prob. 17RQCh. 17 - What are some of the features that may be...Ch. 17 - What features have contributed to the expanded use...Ch. 17 - What are some of the uses or applications of...Ch. 17 - Prob. 21RQCh. 17 - Prob. 22RQCh. 17 - Prob. 23RQCh. 17 - What type of information about the material being...Ch. 17 - Prob. 25RQCh. 17 - Why is friction such an important parameter in...Ch. 17 - Why are friction effects in metalworking difficult...Ch. 17 - Prob. 28RQCh. 17 - Prob. 29RQCh. 17 - Prob. 30RQCh. 17 - Prob. 31RQCh. 17 - Discuss the significance of wear in metal forming:...Ch. 17 - Lubricants are often selected for properties in...Ch. 17 - What is tribology?Ch. 17 - What are some of the common types of metal forming...Ch. 17 - What is hydrodynamic lubrication? What are some of...Ch. 17 - If the temperature of a material is increased,...Ch. 17 - Define the various regimes of cold working, warm...Ch. 17 - What is an acceptable definition of hot working?...Ch. 17 - What are some of the attractive manufacturing and...Ch. 17 - What are some of the negative aspects of hot...Ch. 17 - Prob. 42RQCh. 17 - Prob. 43RQCh. 17 - If the deformed grains recrystallize during hot...Ch. 17 - Why might a rolled thread offer improved strength...Ch. 17 - How might the temperature of a deforming workpiece...Ch. 17 - Why are heated dies or tools often employed in...Ch. 17 - What generally restricts the upper temperature to...Ch. 17 - What is the primary cause of residual stresses in...Ch. 17 - What is cold working?Ch. 17 - Compared to hot working, what are some of the...Ch. 17 - What are some of the disadvantages of...Ch. 17 - How could cold working be used to reduce the cost...Ch. 17 - Why are cold�forming processes best suited for...Ch. 17 - How can the tensile test properties of a metal be...Ch. 17 - Why is elastic springback an important...Ch. 17 - What is pickling, and how does it remove surface...Ch. 17 - Prob. 58RQCh. 17 - What engineering properties are likely to decline...Ch. 17 - Prob. 60RQCh. 17 - Prob. 61RQCh. 17 - Prob. 62RQCh. 17 - What are some of the advantages of warm forming...Ch. 17 - Prob. 64RQCh. 17 - What material feature is considered to be the...Ch. 17 - Why is isothermal forming considerably more...Ch. 17 - Prob. 67RQCh. 17 - Prob. 1PCh. 17 - Prob. 2PCh. 17 - List and discuss the various economic factors that...Ch. 17 - Prob. 4PCh. 17 - Prob. 5PCh. 17 - Prob. 6PCh. 17 - Prob. 1.1CSCh. 17 - Prob. 1.2CSCh. 17 - Which stainless steel would you recommend? Begin...Ch. 17 - Prob. 1.4CSCh. 17 - Prob. 1.5CSCh. 17 - After drawing and perforating, the residual...Ch. 17 - One of the blades has struck a rock and is badly...Ch. 17 - A second propeller, identical to the one above,...
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- Estimate the power for annealed low carbon steel strip 200 mm wide and 10 mm thick, rolled to a thickness of 6 mm The roll radius is 200 mm, and the roll rotates at 200 rev/min; use coefficient of friction at the die-work interface (u)= 0.1. A low carbon steel such as AISI 1020 has K (strength coefficient) = 530 MPa and n ( strain hardening exponent) = 0.26 a) 1059 kW b) 950 kW C) 1183 kW d) 875 kWarrow_forwardA cylindrical workpiece of 100mm diameter and 150mm in height (Fig. 1) is upset (open die forged) at 1200° C to 100mm height disk (Fig. 2). Material of the workpiece is low carbon steel. A graphite lubricant reduces the friction to u=0.25. A press with 2-m/sec speeds is used to make this part. At 1200° C the material has the values for its C=48MPA and m=0.08 parameters Fig. 1 Height=150mm, Diameter=100mm Fig. 2 Height = 100mm, Diamete = ? mm (a) (b) (c) Determine the final diameter of the disk (see Fig. 2) Determine the true strain rate at the end of process. Calculate the flow stress at the end of the stroke.arrow_forward7. A strip of annealed low-carbon steel (K = 528 MPa, n = 0.25) is rolled from its initial dimensions (210 mm wide and 13 mm thick) to a thickness of 7 mm. The rollers have a radius of 250 mm, the roller rotates at 200 rpm, and u = 0.1. Compare this high frictional force and power with the low frictional (u = 0) forces and power. a. Estimate the roll force and power required for this process.arrow_forward
- Q/ A plate of 270 mm wide and 25 mm thick from carbon steel. A two-high rolling mill is used to reduce the thickness to 20 mm. Roll radius = 600 mm, and roll speed = 8 rpm. Strength coefficient = 500 MPa, and strain hardening exponent = 0.25. Determine (a) roll force, (b) roll torque, and (c) power required to perform the operation.arrow_forwardComplete the following table comparing cold, warm and hot work: Note: Preferably, if possible, the answer should be digital, not on a physical sheet. :3arrow_forwardThe thickness of a sheet is reduced by rolling (without any change in width) using 600 mm diameter rolls. Neglect elastic deflection of the rolls and assume that the coefficient of friction at the roll-workpiece interface is 0.05. The sheet enters the rotating rolls unaided. If the initial sheet thickness is 2 mm, the minimum possible final thickness that can be produced by this process in a single pass isarrow_forward
- Define specific energy for plane strain machining (cutting). In plane-strain machỉning, the two main sources of energy dissipation are deformation along the shear plane (~70%) and friction at the tool-chip contact along the rake face (~30%). Consider machining of a rigid perfectly-plastic work material whose uniaxial yield stress is 700 MPa, and is independent of strain rate and temperature. A tool of zero-degree rake angle is employed. Measurements showed the (deformed) chip thickness to be twice that of the undeformed chip thickness. Based on the aforementioned distribution of energy, estimate the specific energy for this process.arrow_forwardCorrect and complete solution please don't copyarrow_forward2)arrow_forward
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