SOLUTIONS MANUAL

FUNDAMENTALS OF
MODERN
MANUFACTURING:
MATERIALS, PROCESSES, AND SYSTEMS

Second Edition

MIKELL P. GROOVER
Professor of Industrial and Manufacturing Systems Engineering
Lehigh University

John Wiley & Sons, Inc., New York

1
 curve defined by: K = 600 MPa and n = 0.12. Determine the force in the operation (a) just as the
yield point is reached (yield at strain = 0.002), (b) at h = 30 mm, and (c) at h = 20 mm.
Solution: (a) V = pD2L/4 = p(50) 2(40)/4 = 78,540 mm3
Given e = 0.002, Yf = 600(0.002) 0.12 = 284.6 MPa, and h = 40 - 40(0.002) = 39.92
A = V/h = 78,540/39.92 = 1963.5 mm2
Kf = 1 + 0.4(.2)(50)/39.92 = 1.1
F = 1.1(284.6)(1963.5) = 614,693 N
(b) Given h = 30, e = ln(40/30) = ln 1.333 = 0.287
Yf = 600(0.287) 0.12 = 516.6 MPa
V = 78,540 mm3 from part (a) above.
At h = 30, A = V/h = 78,540/30 = 2618 mm2
Corresponding D = 57.7 mm (from A = pD2/4)
Kf = 1 + 0.4(.2)(57.7)/30 = 1.154
F = 1.154(516.6)(2618) = 1,560,557 N
(c) Given h = 20, e = ln(40/20) = ln 2.0 = 0.693
Yf = 600(0.693) 0.12 = 574.2 MPa
V = 78,540 mm3 from part (a) above.
At h = 20, A = V/h = 78,540/20 = 3927 mm2
Corresponding D = 70.7 mm (from A = pD2/4)
Kf = 1 + 0.4(.2)(70.7)/20 = 1.283
F = 1.283(574.2)(3927) = 2,892,661 N
19.15 A cylindrical workpart with D = 2.5 in and h = 2.5 in is upset forged in an open die to a height =
1.5 in. Coefficient of friction at the die -work interface = 0.10. The work material has a flow curve
defined by: K = 40,000 lb/in2 and n = 0.15. Determine the instantaneous force in the operation (a)
just as the yield point is reached (yield at strain = 0.002), (b) at height h = 2.3 in, (c) h = 1.9 in, and
(d) h = 1.5 in.
Solution: (a) V = pD2L/4 = p(2.5) 2(2.5)/4 = 12.273 in 3
Given e = 0.002, Yf = 40,000(0.002) 0.15 = 15,748 lb/in2 and h = 2.5 - 2.5(0.002) = 2.495
A = V/h = 12.273/2.495 = 4.92 in 2
Kf = 1 + 0.4(.1)(2.5)/2.495 = 1.04
F = 1.04(15,748)(4.92) = 80,579 lb
(b) Given h = 2.3, e = ln(2.5/2.3) = ln 1.087 = 0.0834
Yf = 40,000(0.0834) 0.15 = 27,556 lb/in2
V = 12.273 in 3 from part (a) above.
At h = 2.3, A = V/h = 12.273/2.3 = 5.34 in 2
Corresponding D = 2.61 (from A = pD2/4)
Kf = 1 + 0.4(.1)(2.61)/2.3 = 1.045
F = 1.045(27,556)(4.34) = 153,822 lb
(c) Given h = 1.9, e = ln(2.5/1.9) = ln 1.316 = 0.274
Yf = 40,000(0.274) 0.15 = 32,948 lb/in2
V = 12.273 in 3 from part (a) above.
At h = 1.9, A = V/h = 12.273/1.9 = 6.46 in 2
Corresponding D = 2.87 (from A = pD2/4)
Kf = 1 + 0.4(.1)(2.87)/1.9 = 1.060
F = 1.060(32,948)(6.46) = 225,695 lb

106
 (d) Given h = 1.5, e = ln(2.5/1.5) = ln 1.667 = 0.511
Yf = 40,000(0.511) 0.15 = 36,166 lb/in2
V = 12.273 in 3 from part (a) above.
At h = 1.5, A = V/h = 12.273/1.5 = 8.182 in 2
Corresponding D = 3.23 (from A = pD2/4)
Kf = 1 + 0.4(.1)(3.23)/1.5 = 1.086
F = 1.086(36,166)(8.182) = 321,379 lb
19.16 A cylindrical workpart has a diameter = 2.0 in and a height = 4.0 in. It is upset forged to a height =
2.5 in. Coefficient of friction at the die -work interface = 0.10. The work material has a flow curve
with strength coefficient = 25,000 lb/in 2 and strain hardening exponent = 0.22. Determine the plot
of force vs. work height.
Solution: Volume of cylinder V = pD2L/4 = p(2.5) 2(4.0)/4 = 19.635 in 3
We will compute the force F at selected values of height h: h = (a) 4.0, (b) 3.75, (c) 3.5, (d) 3.25,
(e) 3.0, (f) 2.75, and (g) 2.5. These values can be used to develop the plot. The shape of the plot
will be similar to Figure 21.13 in the text.
(a) At h = 4.0, we assume yielding has just occurred and the height has not changed significantly.
Use e = 0.002 (the approximate yield point of metal).
At e = 0.002, Yf = 25,000(0.002) 0.22 = 6,370 lb/in2
Adjusting the height for this strain, h = 4.0 - 4.0(0.002) = 3.992
A = V/h = 19.635/3.992 = 4.92 in 2
Kf = 1 + 0.4(.1)(2.5)/3.992 = 1.025
F = 1.025(6,370)(4.92) = 32,125 lb
(b) At h = 3.75, e = ln(4.0/3.75) = ln 1.0667 = 0.0645
Yf = 25,000(0.0645) 0.22 = 13,680 lb/in2
V = 19.635 in 3 calculated above.
At h = 3.75, A = V/h = 19.635/3.75 = 5.236 in 2
Corresponding D = 2.582 (from A = pD2/4)
Kf = 1 + 0.4(.1)(2.582)/3.75 = 1.028
F = 1.028(13,680)(5.236) = 73,601 lb
(c) At h = 3.5, e = ln(4.0/3.5) = ln 1.143 = 0.1335
Yf = 25,000(0.1335) 0.22 = 16,053 lb/in2
At h = 3.5, A = V/h = 19.635/3.5 = 5.61 in 2
Corresponding D = 2.673 (from A = pD2/4)
Kf = 1 + 0.4(.1)(2.673)/3.5 = 1.031
F = 1.031(16,053)(5.61) = 92,808 lb
(d) At h = 3.25, e = ln(4.0/3.25) = ln 1.231 = 0.2076
Yf = 25,000(0.2076) 0.22 = 17,691 lb/in2
At h = 3.25, A = V/h = 19.635/3.25 = 6.042 in 2
Corresponding D = 2.774 (from A = pD2/4)
Kf = 1 + 0.4(.1)(2.774)/3.25 = 1.034
F = 1.034(17,691)(6.042) = 110,538 lb
(e) At h = 3.0, e = ln(4.0/3.0) = ln 1.333 = 0.2874
Yf = 25,000(0.2874) 0.22 = 19,006 lb/in2
At h = 3.0, A = V/h = 19.635/3.0 = 6.545 in 2
Corresponding D = 2.887 (from A = pD2/4)

107
 Kf = 1 + 0.4(.1)(2.887)/3.0 = 1.038
F = 1.038(19,006)(6.545) = 129,182 lb
(f) At h =2.75, e = ln(4.0/2.75) = ln 1.4545 = 0.3747
Yf = 25,000(0.3747) 0.22 = 20,144 lb/in2
V = 19.635 in 3 calculated above.
At h = 2.75, A = V/h = 19.635/2.75 = 7.140 in 2
Corresponding D = 3.015 (from A = pD2/4)
Kf = 1 + 0.4(.1)(3.015)/2.75 = 1.044
F = 1.044(20,144)(7.140) = 150,136 lb
(g) At h = 2.5, e = ln(4.0/2.5) = ln 1.60 = 0.470
Yf = 25,000(0.470) 0.22 = 21,174 lb/in2
At h = 2.5, A = V/h = 19.635/2.5 = 7.854 in 2
Corresponding D = 3.162 (from A = pD2/4)
Kf = 1 + 0.4(.1)(3.162)/2.5 = 1.051
F = 1.051(21,174)(7.854) = 174,715 lb
19.17 A cold heading operation is performed to produce the head on a steel nail. The strength coefficient
for this steel is K = 550 MPa, and the strain hardening exponent n = 0.24. Coefficient of friction at
the die-work interface = 0.10. The wire stock out of which the nail is made is 4.75 mm in diameter.
The head is to have a diameter = 9.5 mm and a thickness = 1.5 mm. (a) What length of stock must
project out of the die in order to provide sufficient volume of material for this upsetting operation?
(b) Compute the maximum force that the punch must apply to form the head in this open-die
operation.
Solution: (a) Volume of nail head V = pDf2hf/4 = p(9.5) 2(1.5)/4 = 106.3 mm3.
Ao = pDo2/4 = p(4.75) 2/4 = 17.7 mm2
ho = V/Ao = 106.3/17.7 = 6.0 mm
(b) e = ln(6.0/1.5) = ln 4 = 1.3863
Yf = 550(1.3863) 0.24 = 595 MPa
Af = p(9.5) 2/4 = 70.9 mm2
Kf = 1 + 0.4(.1)(9.5/1.5) = 1.25
F = 1.25(595)(70.9) = 52,872 N
19.18 Obtain a large common nail (flat head). Measure the head diameter and thickness, as well as the
diameter of the nail shank. (a) What stock length must project out of the die in order to provide
sufficient material to produce the nail? (b) Using appropriate values for strength coefficient and
strain hardening exponent for the metal out of which the nail is made (Table 3.5), compute the
maximum force in the heading operation to form the head.
Solution: Student exercise. Calculations similar to those above for the data developed by the
student.
19.19 A hot upset forging operation is performed in an open die. The initial size of the workpart is: Do =
25 mm, and h o = 50 mm. The part is upset to a diameter = 50 mm. The work metal at this elevated
temperature yields at 85 MPa (n = 0). Coefficient of friction at the die -work interface = 0.40.
Determine: (a) final height of the part, and (b) maximum force in the operation.
Solution: (a) V = pDo2ho/4 = p(25) 2(50)/4 = 24,544 mm3.
Af = pDf2/4 = p(50) 2/4 = 1963.5 mm2.
hf = V/Af = 24,544 /1963.5 = 12.5 mm.

108
 (b) e = ln(50/12.5) = ln 4 = 1.3863
Yf = 85(1.3863) 0 = 85 MPa
Force is maximum at largest area value, Af = 1963.5 mm2
D = (4 x 1963.5/p)0.5 = 50 mm
Kf = 1 + 0.4(.4)(50/12.5) = 1.64
F = 1.64(85)( 1963.5) = 273,712 N
19.20 A hydraulic forging press is capable of exerting a maximum force = 1,000,000 N. A cylindrical
workpart is to be cold upset forged. The starting part has diameter = 30 mm and height = 30 mm.
The flow curve of the metal is defined by K = 400 MPa and n = 0.2. Determine the maximum
reduction in height to which the part can be compressed with this forging press, if the coefficient of
friction = 0.1.
Solution: Volume of work V = pDo2ho/4 = p(30) 2(30)/4 = 21,206 mm3.
Final area Af = 21,206/hf
e = ln(30/hf)
Yf = 400e 0.2 = 400(ln 30/hf)0.2)
Kf = 1 + 0.4m(Df/hf) = 1 + 0.4(0.1)(Df/hf)
Forging force F = KfYfAf = (1 + 0.04D f/hf)( 400(ln 30/hf)0.2)( 21,206/hf)
Requires trial and error solution to find the value of hf that will match the force of 1,000,000 N.
(1) Try hf = 20 mm
Af = 21,206/20 = 1060.3 mm2
e = ln(30/20) = ln 1.5 = 0.405
Yf = 400(0.405) 0.2 = 333.9 MPa
Df = (4 x 1060.3/p)0.5 = 36.7 mm
Kf = 1 + 0.04(36.7/20) = 1.073
F = 1.073(333.9)(1060.3) = 380,050 N
Too low. Try a smaller value of hf to increase F.
(2) Try hf = 10 mm.
Af = 21,206/10 = 2120.6 mm2
e = ln(30/10) = ln 3.0 = 1.099
Yf = 400(1.099) 0.2 = 407.6 MPa
Df = (4 x 2120.6/p)0.5 = 51.96 mm
Kf = 1 + 0.04(51.96/10) = 1.208
F = 1.208(407.6)(2120.6) = 1,043,998 N
Slightly high. Need to try a value of hf between 10 and 20, closer to 10.
(3) Try hf = 11 mm
Af = 21,206/11 = 1927.8 mm2
e = ln(30/11) = ln 2.7273 = 1.003
Yf = 400(1.003) 0.2 = 400.3 MPa
Df = (4 x 1927.8/p)0.5 = 49.54 mm
Kf = 1 + 0.04(51.12/11) = 1.18
F = 1.18(400.3)(1927.8) = 910,653 N
(4) By linear interpolation, try hf = 10 + (44/133) = 10.33 mm
Af = 21,206/10.33 = 2052.8 mm2
e = ln(30/10.33) = ln 2.9042 = 1.066
Yf = 400(1.066) 0.2 = 405.16 MPa

109
 Df = (4 x 2052.8/p)0.5 = 51.12 mm
Kf = 1 + 0.04(51.12/10.33) = 1.198
F = 1.198(405.16)(2052.8) = 996,364 N
(5) By further linear interpolation, try hf = 10 + (44/48)(0.33) = 10.30
Af = 21,206/10.30 = 2058.8 mm2
e = ln(30/10.30) = ln 2.913 = 1.069
Yf = 400(1.069) 0.2 = 405.38 MPa
Df = (4 x 2058.8/p)0.5 = 51.2 mm
Kf = 1 + 0.04(51.2/10.3) = 1.199
F = 1.199(405.38)(2058.8) = 1,000,553 N
Close enough! Maximum height reduction = 30.0 - 10.3 = 19.7 mm
19.21 A part is designed to be hot forged in an impression die. The projected area of the part, including
flash, is 15 in 2. After trimming, the part has a projected area = 10 in 2. Part geometry is relatively
simple. As heated the work material yields at 9,000 lb/in 2, and has no tendency to strain harden.
Determine the maximum force required to perform the forging operation.
Solution: Since the work material has no tendency to work harden, n = 0.
From Table 21.1, choose Kf = 6.0.
F = 6.0(9,000)(15) = 810,000 lb.
19.22 A connecting rod is designed to be hot forged in an impression die. The projected area of the part
is 6,500 mm2. The design of the die will cause flash to form during forging, so that the area,
including flash, will be 9,000 mm2. The part geometry is considered to be complex. As heated the
work material yields at 75 MPa, and has no tendency to strain harden. Determine the maximum
force required to perform the operation.
Solution: Since the work material has no tendency to work harden, n = 0.
From Table 21.1, choose Kf =8.0.
F = 8.0(75)(9,000) = 5,400,000 N.

Extrusion
19.23 A cylindrical billet that is 100 mm long and 40 mm in diameter is reduced by indirect (backward)
extrusion to a 15 mm diameter. Die angle = 90°. If the Johnson equation has a = 0.8 and b = 1.5,
and the flow curve for the work metal has K = 750 MPa and n = 0.15, determine: (a) extrusion
ratio, (b) true strain (homogeneous deformation), (c) extrusion strain, (d) ram pressure, and (e) ram
force.
Solution: (a) rx = Ao/Af = Do2/Df2 = (40) 2/(15) 2 = 7.111
(b) e = ln rx = ln 7.111 = 1.962
(c) e x = a + b ln rx = 0.8 + 1.5(1.962) = 3.742
(d) Y = 750(1.962) 0.15/1.15 = 721.5 MPa,
f

p = 721.5(3.742) = 2700 MPa

(e) Ao = pDo2/4 = p(40) 2/4 = 1256.6 mm2
F = 2700(1256.6) = 3,392,920 N.
19.24 A 3.0-in long cylindrical billet whose diameter = 1.5 in is reduced by indirect extrusion to a
diameter = 0.375 in. Die angle = 90°. In the Johnson equation, a = 0.8 and b = 1.5. In the flow

110