ME 206: Manufacturing Processes I

SE 322: Manufacturing Technology

First Semester 2005-2006 (051)

Problem Set # 4 Prepared by: Dr. A. Arif

Assigned on 21st November, 2005. Due on. 3rd December, 2005

Problem 1 (10 Points)

A magnesium billet of 100mm in diameter and 250mm in length is extruded above its
recrystallization temperature and at a speed of 200 mm/s. The final product has a hollow
circular cross-section of outer diameter 60mm, and inner diameter of 50 mm. Assume poor
lubrication, and using “square” die (which forces materials to flow along 45˙ in the die
region). Calculate the force required to perform the above extrusion process.
Use C=140 MPa, and an average value of m =0.25.

Solution:
Problem 2 (10 Points)
A linearly strain-hardening material with a true-stress- true-strain curve
σ = 5000 + 20000ε psi is being drawn into a wire. If the original diameter of the wire is 0.2
in., what is the minimum possible diameter at the die exit? Assume that there is no redundant
work and the frictional work is 25% of the ideal work of deformation. (Hint. The yield stress
of the existing wire is the point on the true-stress- true-strain curve that corresponds to the
total strain that the material has undergone.)

Solution
Problem 3 (10 Points)
A planned indirect extrusion operation involves copper material at 900 °C, with an initial
diameter of 120-mm and a final diameter of 8-mm. The available press for this operation has
a capacity of 2-MN, a container length of 1.2-m, and a variable ram speed reaching 120mm/s.
What is the maximum volumetric production rate for this operation?
Problem 4 (10 Points)
A flat strip (sheet) of annealed copper 6 mm in thickness, 100 mm wide, is being drawn
through a die at a speed of 0.5 m/sec. It is proposed that a reduction of 25% in thickness is to
be taken in a single pass at room temperature. The material obeys the strain hardening
equation σ = 140ε 0.54 MPa. Assuming no friction and redundant work, Calculate the:
(a) True strain ( ε 1 ) experienced by the strip wire passing through the die.
(b) Average flow stress for the above process.
(c) Ideal drawing force of deformation.
Problem 5 (10 Points)
A wire is drawn from annealed, 3-mm diameter 302 stainless steel wire. The cross-sectional
area of the final wire is 5.0 mm2. A commercial oil-based lubricant is used which makes the
coefficient of friction , µ= .05, the dies have included angle, 2α = 12°, and drawing speed is
2-m/s. Including the frictional and redundant work, calculate the
(a) draw force
(b) feasibility of the operation (whether the draw is possible)
(c) net power requirement
(d) die pressure at the exit