PROBLEM 1
A metal has a flow curve with parameters: K= 750
PROBLEMS
BULK DEFORMATION AND SHEET METAL WORKING
PROBLEM 3
The gage length of a tensile test specimen = 150 mm.
It is subjected to a tensile test in which the grips
holding the end of the test specimen are moved with
a relative velocity = 0.15 m/s.
Construct a plot of the strain rate as a function of
length as the specimen is pulled to a length = 200
mm.
PROBLEM 2
K= 45,000 lb/in2 and n= 0.38 for a metal used in
MPa and strain hardening exponent n= 0.25. A tensile
specimen of the metal with gage length = 150 mm is
stretched to a length = 205 mm.
Determine the flow stress at the new length and the
average flow stress that the metal has been subjected
to during the deformation.
PROBLEM 4
A 2.5 in thick slab is 10.0 in wide and 12.0 ft long. Thickness
is to be reduced in three steps in a hot rolling operation.
Each step will reduce the slab to 65% of its previous
thickness. It is expected that for this metal and reduction,
the slab will widen by 5% in each step. If the entry speed of
the slab in the first step is 35 ft/min, and roll speed is the
same for the three steps,
determine: (a) length and (b) exit velocity of the slab after
the final reduction.
a forming operation in which the workpart is
reduced in cross-sectional area by stretching. If
the average flow stress on the part is 20,000
lb/in2
Determine the amount of increase in lenght
experienced by the part
PROBLEM 5
A series of cold rolling operations are to be used to reduce the thickness of a
plate from 60 mm down to 30 mm in a reversing two -high mill. Roll diameter =
800 mm and coefficient of friction between rolls and work = 0.13. The
specification is that the draft is to be equal on each pass.
Determine: (a) minimum number of passes required, and (b) draft for each
pass?
Suppose now that the percent reduction were specified to be equal for each
pass, rather than the draft.
(a) What is the minimum number of passes required? (b) What is the draft for
each pass?
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PROBLEM 6
A cylindrical part is warm upset forged in an open die. The initial
diameter is 45 mm and the initial height is 40 mm. The height after
forging is 25 mm. The coefficient of friction at the die–work interface
is 0.20. The yield strength of the work material is 285 MPa, and its
flow curve is defined by a strength coefficient of 600 MPa and a
strain-hardening exponent of 0.12.
Determine the force in the operation (a) just as the yield point is
reached (yield at strain 0.002), (b) at a height of 35 mm, (c) at a
height of 30 mm, and (d) at a height of 25 mm.
PROBLEM 7
A billet that is 80 mm long with diameter = 30 mm is
direct extruded to a diameter of 20 mm. The
extrusion die has a die angle = 75°. For the work
metal, K= 650 MPa and n= 0.25. In the Johnson
extrusion strain equation, a= 0.8 and b= 1.4.
Determine: (a) extrusion ratio, (b) true strain
(homogeneous deformation), (c) extrusion strain, and
(d) ram pressure at L= 75, 50, and 25 mm.
PROBLEM 8
An L-shaped part is to be bent in a V-bending operation on a
press brake from a flat blank 4.0 inches by 1.5 inches that is
5/32 inch thick. The bend of 90°is to be made in the middle of
the 4-inch length. (a) Determine the dimensions of the two
equal sides that will result after the ben d, if the bend radius =
3/16 inch. For convenience, these sides should be measured to
the beginning of the bend radius.
Determine the bending force required in Problem 20.11 if the
bend is to be performed in a V-die with a die opening width W =
1.25 inches. The material has a tensile strength = 70,000 lb/in2
.