( M etas for ning ProleSS )

1.1 INTftODUCTlON TO METAL FORMING

A product can by manufactured by any of the following processes: Cn*fiqg.
Farm'ing, Joi’ning, and
Machining.. Each .o(these p ggjtg$ pqt its.own.features and. character.stics
thai:make it
suitable for rianutâctunniapai-ucular product
f’orming'or:beta/ fPnr eg is a process ai which',the desired shape arid size of
th'e component is

o6tained through plants',.deformation of the.metal. simple *°

t1ic,componen1 is'formed
.Without:removing ; y material.fom. it. The suesses mduced in the metal by-
the.spited.foicm
during the forming rficéss arc greaer than the yield strenjth*, but
properties tka« hose 6tain«t by cssti«g or n› ink d»8 Further• the wastage of
the work material
is either negligible or very small, and the production rate in geCyal is very J;igG
witl}the
forming

all manufactured byv'arious forming.processes... . ' ' :

. - '
.. : . : '
1.2 !, CLASSIFICATION.'OF .METAL FORMING PROCJESSES':.J. ''' ' "''

1.2.1 Classincation Based on Force Applied

lftfi nrking temperature ‹›fthe wnrkpiece metal is iibove its below ihe melting
point. the
process is classilicd under I o1 working

siress is. required

a). Pompahents produ‹xxJ tioiTi mc•Ial'forming pnwusses w1\ihit superit›r

mechufticaJ prcj›crties.
b). ñ1ctaJs.are deformed In tkcir pTasdc suite. When suitably carried ouL the,
pmccss minimizes
!. :'. ” ” 6fi ce defalb like.bluw holes, porosity,.cfc.
”c) ’Deske›d s'hape be achieved wi h fitvuumblc changes'in micros\ructurc.
’d} Low.wasiage ofmetol duz'ing waking. Hence more raw mate.Sat savings. .
b) T‹x›lingcosaarekigh
c) Courting oqu*pmnnH require prciper. maintenance ffi their effective f i
ing.
d) Wing. en\rironmcnl- is .r¥x ,gond.. , Operau›r•. need .la work
u .set.loads.aad
tcwtpc›atufcs. ”
” ” : ” ”
e) Notsuitablc for very large components..
i.s c crEaisncs oF..wnoucirr rmonrns.
The Wotd urozigD z the past tcme off v&b'f:o Wrought product
refers'tothose
p'nxiiicts
sñch as leds,.barn, tubes, plaies ami wires ihst are pnxiuccd by Hot or Cold
working process. A
fcW iDl Orldrti Ch8 U9ttC8 OfWFOU products W:hBtd !,bcknv:
” a)””Producls are f‹xmM bydcfbrming tbc metal in its plastic slats.
’ ! ”
'
- b) tracts prods+cms are ductile m nature.
C) They can,bc Identified quickly âj/.’their eurface’’£mish and sharp corners.’
Fr‹xtucts arc
f?cc
” fñmta rsdcim likn bb›w,hotcc,-jxxosi\y. azxl surface
irrcgubffi+es.

1.5. I Krotlgb£ tl£t8. Y/6 8Sfi !P4’4H$ntPtS

’ ’
Table I.2giver a 6nefcomparison between wn›ught pti›ducts and cast pnduns.

3. Wmught products cannot be produced in large size and complex shapes.

4.
5. Wrought products have minimum
defects and surface irregularities.
‘l'here is no restriction to size and shape of cast products.
Cast products can be ductile or brittle, but their propeñies are
slightly lower
than wrought products.
Comparatively more.

Table 1.2 Comparison between wrought product and cast product

i.e., strain (E) -

- Lo wer die

energy by a l‹lrge
small element dr
figure 3.11 (a).
5)

- (45 • 10‘)(1.25)(0.886)= 57.54 • I &

‘f "
After forking

’told stress of work iGCfl ht beginning of forging - (a -— 75 MPa — 75 •

10a N/m’
Yield suss after forging = (Cfp)/= 120 MPa - 120 ^ 10’ N/m'

diametor of bar before torging 0 mmi height ot'bar before forging

= 1 - 100 mm
height of bar after forging = h - 25 mv
Flow stress = n = 100(0.0055 + c)⁰"N/ ii

ep 2 ’IN find a„ P , & Pg at the heginning of plastic deformat

Now equBtioR(2) becomes,

w.k.t. for circular disc, P -

1

93

maximum die pressures at the beginning of plaslic deformation and at the end
ofcompresskin. The
yield strength of the material is given as o= 15.00(0.01 + C)0.41 kgf/mm' d4 I
— 0.06.
Ans: At the beginning of plastic deformation Pp —- 2.31 /mm’ ; Pg —- 2.41
kgf/ ' At
the end of plastic deformation P — 13.75 jam' , Pg‘— 15.38 kgf7 ’
4. A square dIsc having 100 mm side and 25 mm height is compressed between two
flat dim. Determine
the die load at the beginning ofcompression using upper bond solution Take the
value of friction
facior m = 0.3 and yield strength of material in compression 300 N/ *.
Hint : Calculate using P - I
where 2« = 100, &
I; = 25

5. A cylinder of 60 mm height and 20 mv diameter is to be upset to half the heighi

between Oat
dies. The yield strenJ ofthe component at the f0rging tempemtum is 550 MPa.
Circulate:
(a) The maximum force required for upsetting with friction of 0.33 and without
frictions
(b) Find the extra force requaud if friction is present. ME
64 Jan 09 - 06
rri
6. A flat circular disc of 25 mm diameter and thickness 75 mm is to be Purged to
halftiu hcigfa
between fiat faces. Calculate the maximum forging]Oad. Take{1= 0,4 and yield stren
oftfc material
as 40 Atm'. 06ME 73
June 12-06m

7. EsillTlBtfl IG pf&5GBQ&ity necessary for forging a I m long cyimdncal bleom

to a hexapmd
secflon with 300 mm side lengths if the yield stress is initially 75 Num° but
increases to 120
N7mm' ai the end of the operation. Assume (a) that the broom is partially
lubricated so thai p =
0.3, (b) thu there is no lu6ricati‹x , Assume plane strain common.
Tfint : ft is quired to calculate max. forging force (press capacity) under two
.
slidiz\g frictjou c‹›ndition(g = 0.3) and sticking fñcñon cond›t (no
ktbrication). To
2

8. Determine the avemge force ofa hydraulic press required to upset a low cartxni
steel blmk of
diameter 250 mm and height 300 mm to a height of 200 mv. A88ume a= 60Mn W
9=0.33.

Ans:
=S.d
9. A solid cylindrical slug made of stainless steel is 150 mv diameter and 100 met
ffigbt. If ñ
reduced in heignt by 50% at rmm temperature byopen die forging with flat dicn
Asnanepm
0.2 and flow stress as 1000 MPa, calculate forging force at tire end of the stmke.
10ME 55 Ian 14-08 nt

Hlnt : take tlow stress o = 1000 .HPa

la:s: Fq = 47 85 If
w.kt%

127'

’.’ ——(4)

From equatioa{4), we have Hi 2 ' 0

4
1’0’0’
”” ’.x0.1

= 4.63 in,mdianmode

us'mg equafion(3), we.l;ave’ Mfg’

I 4.63—
2
1 5’
0.1. 4

= 1.2

‘Now equation,(2) becomes; ’8,. =

4 UJ

Problem 11 . ’In a -high miliug mill, 25 mm thick m’il0 steel plstes ae rofled
to 20 mm.
Detemme, the coefFicisnt of frlction if this is the maximum reduction possible. The
roll danieter
1s 500 mm.’ Locate the neutral plane, and the, maximum All pressure at thls point.
Take,the yield
strength of mlld,steel.A simple tensfoa ac 12,0 3fPm
Solutian :
.Initial thickness ofplak = o 25-mri-= 0.025 m
Flnal ibickees9 ofplate =. £¿r.20 mm = 0.02-m
Ro§diam«er 500iiiiñ, .'. Rofl-ahus A=250/mm = 0.25 m.
Tensile yield stress= p₀ ’1203fPo=,l20 > lfP N/m2
Step 1 To find poeffiéient offricdog (p) -
 )p sx io '

=0.02 ’’

’or- p = 0.141 ’’
Step 2 To fiad neutral point (8 )
ie.:,,W•. =.

4 = 236.

ft = 6.105

Equation (4} beers, // - —' 6.I 0S - ’

2 0.04
H — 1.383

Now, equatipp (3)becomes, 8, -

In 4
35
x 10 1383
0.25 025 2
B- 9.7 ^ lH’ Indians or 0.55°
. . Equation (2) bemmes, s, = (3.5 • 10 ') + 2 (0.25) I — cos (9.7 • IN')}
6 = 3.52 • 10°m

Unit — 5
reduced \vbe dlameter and

diameter.of the mandrel is eq'ual (practically, it is slightly larger’ being drawn.

Figure 5.10
illuxnates the process in its simplest ft

o’ (250)= 288.6 NWm¹

and B -— q cor n —
B —‘ 0.17
tan n =
0.03
tan l0°
= 0.17

Now, equation (l) become0s

₂ =288.6
(1 + 0.17) l -
0.17
5,625 )0. t7
6.25
-. draw stress n, = 35.26 N/mmⁱ
Step 2 To find draw slrese (a ) with back pull

with bBck pull, we have Ci₂ =

given back pulling force - I= 150 N

Farcc
w.k.t stress = Area
150
!duction in a 10 mm stainless steel Swire e die gle is 12.° and!tlie. g
is .0:09. wire is
moving through the'die at 3 Wi

Oil' ib.i
Foroe F
ig dies are single operation dies, designed n hangs the shape of the work metal
by deforming No
cutting takes place in these dies. These dies are used to change the sham fl
SEC configuration
of metal bktnks. Figure 7.14 shows the bending die.

in metal forming. ier and if fi < 1, it is

Sheet Meta1‘FOf7f1’f“f2
199

The forming limit,diagram gives an indication whether the material can,sustain

ce<ain ratio of
strains without failing. To.produce the,forming -limit diagram, a hbomtorytat is
carried out on
the sheet metd.’ The ,surface of the sheet metal is, printed by a grid of circles
by,electrochemical,, marking process. When the sheet is deformed vder loading
conditions, the
circles distort into ellipses. The major & minor axis ofan,ellips,e represents the
two principal
strain directions in the forming.operation. The strain in these two directions is
measured by the
pe<entage change in the lengths ofthe'major & minor axis. These strains, at,any
point oti the
surface are then compared with the standanl forming diagram shown in figwe 7.19.
,Stiainvalues abo!vc the curve iepmsents, failure, those below donot cause failure,
i.e., assumed
to be safe For example point A’located onthe forming limit diagram represents
failwe conditioq
. ' ... .
.
.. .
howeverifles>ain,distnbulion is alRred, forexample'bychanging the Ie radiis, it
cou1dmove,to
point B, which would not cause failure.

7.7 DEFECTS IN DEEP DRAWN’ PRODUCTS

In deep iJrawing process,,a punch pushes a sheet metal blank deep into a die
«avity,resulting in a
contoured part, The part thus obtained may cqntain various defeGs due to variety
of reasons
involved in,theprocess. A few imp»rtant,ones,are discussed Selow.
a) Wrinkling
A majordefectindeepdawing is,@wrinkling oftlie sheet,inaterial, generalJy-in %e
wall or flafige,
ofthe part. Refer figure 7.20 (a). Themovement,ofthe
blankintolediecavityinducescompressive
,stresses m,,the flange causipg the sheet,to buckle !ocaMy and leading to wrialde
defect. The
defect ian be reduced b,y keeping the sheet blank holder under the
effect of,sufficient
holding, force/pressure. Excessive clearance bétween Ie punch-and die is also
one of the
reasons:and should be considered accordingly.

Tearingandexcessivethinniag›0cculJdueio improper
%rcedistributionindirie&ñiéntblank’shape.
Usually,maximumthinning ofthecup walloccurs nearthebase. Higher
punchforcesusuallycause atear,inthe
weakest,spot, predominantly in the cup wall near the'base. For this reason the
blaak ho!derforce
must not,fie too high..

Earing is the fomiation of wavy edges at ie open end'of the cup. Refer figure
7.20 @). This
occurs,due to directional properties, of the metal because most metals deform more
easily in some
directions than in others:- Such,defects are usually,trimmed in subsequent process.
The,anisotropy
of a particular sheet metalblank is ie, predominant source of caring.
d) Surface scratches/irregularities
Surface scratches or irregularities may appear,on drawn parts due to the rough
surface ofpuñch and
die. Other causes ofsurface'scratching could be improper clearance, or
inadequate..lubricaion.,

Fmblaaking opelatioA dren=*— °‘ °°^

puachsize = b1aaksize-2C where C-— Clearance= 0.003 t s
= 0.003 (2) 310= 1.86 mzn
.-. bomequaaon(l), punchsize=30—2(1.86)=2618 mm
Thus, die aize - 30 <a @HRC &lze = 26.28 mM

Die

To estimate puach force tO

w.kt, cuttie8 fwscr -*p i
where p =pgfingigr@cut= gD for circular profile
=’310 @ p 30) 2r 58.43 • US
. . Punch force = P= 58.4 2N

Stripping force is dg force required tostripthestockmatcrial >*°>°P""'°> w.Lt.

stripping fores =
$P= 0.02 P f kN
= 0.02 (a* D) t
= 0.0 (n x 30) 2= 3.77 2ñf

Note
.usuanyiaPsinefomvarksaom5*°>">•ofg'''icbisg*•*• **•**'°"•"••,
forcevarieswiaa<;g» efmaterialmdtb
,

Dian«»ror‹ta» = D—2o»i»i

’’ sbeir ntress v , 2942fPa=294N/mmi

,Cast 1 Dieñ punch size fwbtaakiag
z 'Fnrbhfiking,diesize, ^ blank9ize=20 mm,
,.-.„Pmlcfisize-:. ,bimksize='2i? where.clearance .= ,C= 0.&3 iT ’’
= 0.&3 J}.5) 294r 132 vm
.•. &mequation(1jpé&ve, pimch@e—M-3(l:3g) 17.36 m•
t”

". ”17..30””

20.mm

’Blanking ””
To find puach fome,(f}
w.kt. i:uttiiig force = /.—. tp r - - -
206

= 0.02 ( • 20)1.5 = 1.88

. . SF - 1.88 kN
Manufacturing Process - III
Problem 4 It is required to punch a hole of 10 mm diameter in a mild steel
plate of l0mm
thickness. If the shear strength of the plate material is 600 NZmm2 &
the compression
strength of the punch material is 200 NZmm2. determine whether the hole can be
punched or not. If
not suggest an alternative.
SO1UtIOR :
Diameter ofhole = D -- 10 mv
Plate thickness = i — 10 mm
x —600 N7mm’
'2000///mm²
Ifa hole has to be punched, then the capacity ofthe punch must be greater than the
force requised
to punch the plate.
w.k.t. cutting force for punching hole= F - r Pt
x {n.D) t where perimeter P -- n.D
= 600 (x = 10) 10= 188.§ x l03
F -- 188.5 kN
To find punch capacity

w.k.t. stress required to cause defomatio

or Force F —— a . A
——(l)
Capacity ofa punch is calculated as the force which a punch can withstand without
failure. From
equation (l), we can write
punch forcC "p ‘ ’ A

= 2000 ( 4 °' Punch size = Blank size= 10 mm

= 2000 4 (10)² 157 103N
punch force Fp -- 157 kN
Thus N (157 < Fqq(188.5 . Hence the hole cannot be punched. The hole can
be made by
drilling operation
Problem 5 A rectangular blank of 20 > 25 mm is to be cut from a 1.5 mm thick
metal strip.
Calculate the blanking force and the work done if the percentage penetration ii
20% of the
material thickness. Take z = 450 N/mm! for the metal strip.

Sheet Meial Forming

207

Let the length ofhole -- a= 20 mm

width ofhole = b -- 25 mm
thickness ofplate = 1.5 mm
percentage penteration = P= 20% = 0.2
z = 450 NZmm2
To find blanking force (N )
w.k.t. cutting force F -- x.P.t where P -- 2(a + b)
= z . [2 (a + b) t
= 450 [2(20+25)] 1.5 = 60.75 10'
F -- 60.75 kN
To find work done
w.k.t. work done = Force distance

Since % penetration is given, work done = F . I p

= (60.75 103)1.5 (0.2)= 18.2 • 10'
. . work done -- 18.2 • 10* N-mm ---- 18.2 Joules
Problem 6 Calculate the maximum punch force and the work done required to blank
a steel washer
44.45 min outside diameter and 22.3 inside diameter from a 1.59 mv thick
rectangular sheet with
as ultimate shear stress of 432 N/mm', and if the % penetration is 25%.
10ME55 July 14
- 08 m
Solution : Figure below shows the details of the washer

t = 1.59mm

22.3 mm

mm

To find maximum punch force F

w.k.t. cutting force = Fqq - z .P t
where Perimeter P -- (P) , + (P) ,
n.D + n D, - n (f›0 + D )

= n(44.55 + 22.3)=209.85 mm “
equation(1) becomes = -432(209.85) 1.59
Cntting fome /, = 14d.14 m’
To find work done
Giwn % Penetration p -25% - 0.25
w.Lt. Work done = F . I @)
(144.14 10*) (l.59@225 —57.3 ^ lfP
Workdone — 57.3 2N-mm =fi7J Joules’ (1J= 1 Y-m)
Problem 7 Calculate the beodipg force £o aJ3° bend of aluminum sheet 1.8 uu
and 120g mm jo@
wi b adlfl opeglgg or 8 ttmw the uetal &ekaess. me bend b &
made by at’ bending methoA Take ultimatc. tn6gfl „s43m of the metal
34If N
SHuaoa:
. › . -- „„
Slieettbickams = r=1.8 mm Sheet leqgth = l2fDmm wkl&ofdic — 8 z
- j$(1.8)= 144 met
-.w.Lt. Ba@gg forge = F,=. k Lat '
where k = die opéfiip$ $ictor= 1.33, fO P=8f

lZ3xl20Dx3Mx(M) 14.4

= lZ2 ^ lfP
Bcndlag top = 122 k/Y
Problem 8 A90° b•ad Is tob•#•sd• frem ateétsl•eat by aJr beodiW pzooess.31ta
length 1s 30 em, thickness of wheat 3 m M,d w IU’d The Dlllmato tmslk »

Laogtb=£ 30c»s=3tOm»t
* 91

210
•’‘ Manufacturing •

w.Lt. Blair dimeter = D - Jd +4W

-- 7 +4(7 )(200) =Z36.17mm

Thus D - 256.17 rim, arid fts areal --4

a) 1^ draw-- 50% reduction

L< dl be ie diameter after first dnwiag, 1, be the height after first dmwing,
and
P, be the percentage reduction= 50% = 0.5

w.k.t. % reduction in l^ draw P|

0.5 =
D- d D
256.17 -- d
256il7

.-. d, -- 128.08 mm,and d, = -J d,'= 12.88 • 10* riri' To find height of work
achieved in l•
draw(AJ)

w kt £ =
” ' i
(5lJ4 -- l22i8) x io' s(128.08)

=96.08 mm
Thus, after 1"draw, diameterofwoAd, -- 128.08 mmaad height= 96.08 mv
:
b) 2 draw -30% r&n«J•
Let d2 = diameter after 2 draw ñJ = height afier 2^ draw
P2 - Percent roducaon= 30%= 0.3
d, - dz

w.kt. % r&uctionin 2^ dra• 2

d;
128.08 - d2 128.08

. d2 = 89.65 mm, •'* * ' 4 d22 = 6.31 ^ 10' mm²

To find height of work achieveit izi 2•‘ draw (h )
J -J2 (51J4-6.31)x l0'

w.k.t. h2 =
2 n(89.65)
. h — 160.6mm
l2S,after 2“ draw, diameter of work d2= 89.65 mm and height= 160.6 mm
e) 3^ draw — 20% reduction
Let d, - diameter aAer 3* draw
h — height aAer 3°draw
P, percentage reduction= 20°o= 0.2

dz
0J 89.65— dz
89.65

d - 71.72 nm; .•. d

To fund height of cork achieved in 3^ draw (At
= 4.04 102 2

w.k.t. h A- A, _ (51J4 —4 04) x io'

ndJ x(7172)
. . h - 210.8mm
Thus it is clear that after the 3* drawingoperation at 20% reductioi, the diameterd
- 71.72 xm
less desired cup diameter 75 = 210.8
mm 1s
desired 200 mri. Hence, thepercentagereductioninthe3^ draw must bclesserthan 20%
iaonler
to obtain %o desired cup dimensions.
To fifnd actual percentage reductionin the 3^ draw
Let Ph be the acNal percent reduction done after 30% reduction in ord> to obtain 75
mm cu & 200 mm
héght

w.k.t. Ph =
d - dz
d2
89.65-75
89.65

-0.163

Thus Ie
30%
or P, -- 16.3%
sheet metal must be drawn to 16.3⁰r.» a‹ 3° reducfion adw ie second reduction of

212

Answers: Number of draw stages required - 3 draws

1" draw = 50%, 2" draw = 30%, and 3" draw = 16.3 %
Note If asked to calculate the drawing force, proceed as fo'llows.
w.k.t. drawing force F —— r d I a !! - c
where C — Constant to cover bending & friction
• C — 0.6 — 0.7
Problem 10 Calculate the number of redraws assuming 50%, 40% & 30% reduction

in 3—stages. The final size of the cup required

is 75 mm diameter & 200 on height.
Determine the height of each draw and the force required for each reduction of the
shee£

Take o = 600 3fPu, and f = 4 riri. Solution :

ME64 Jan’09 — 06 m
diameter ofcup = d—— 75 mm height ofcup = â ——200 mv
w.k.t. Blank diameter = D —— jtd² + 4dh
= 7 + 4 75)(200) — 256.17

Blank diameter D — 256/ 17 mm : .-. Arid A —— ₄D2 = 51.54 10 m<'

a) 1 draw — 50% reduction
Let d, be the diameter & /i, be the height of cup after 1" drawing.
Percent reduction Al = 50% = 0.5
D - d, D

0.5
256.17 —d,
256.17

. . d, - 128.08 rim and A = 4 d,2 = 12.88 • 10' mm2

A- A -
cup height h =

(51J4 — 12.88) x i0'

tt(l2B.08) = 96.08 mm

h, = 96.08 wm
b) 2°‘ draw --40% reduction
d, -- d2
W.k.t. Ph - d,
0.4 128.08 -- d2
128.08

. . d = 76.84 mm and At --- 4d ² = 4 63 10³ mm2

A- A

w.k.t. height ñ

51d4 -- 4.63) x 10' = 194.32 n(’/6.84)

Thus A₂ = 194.32 mm
c) 3^ draw -- 30% reduction
w.k.t. Ph

0.3
dz -- d,
d2
76.84 -- dz
76.84

d -- 53.78 mv ,’

w.k.t. height h --
4 d,2 = 2.27 10' m²

A - A3

(s1J4--2J7)x10’ x(33.78)
Thus ft -- 291.6 mm

= 291.6
Thus the diameter d3 = 53.78 mm after 3° draw is less than the required 75 mm
diameter, and the
height /i3'291.6 mm is more than the required 200 mm. To obtain the exact cup
dimensions, the 3"
draw must be less than 30%, and is as calculated below.
d
Actual reduction in 3°draw= Ph --
d2

76.84--75

- 0.0239 = 2.39% or approx. 2.4% Hence,bychoosingapproximaR92.4%reductioninne

3°dmw, the required
cup dimensitgg

Thus three drawing opgiatiou are needed to dmw the blink into a i:up of 75 mm dia &
2fD nip
hei@t. I° draw = 500/‹, 2•ᵈ draw= 40%, aad 3“draw= 2.4 %.
To calculate fone requlred for each reduction w.Lt. dravñag, I!orce F - n d t a
wlars t---4 mm•, a --- 600 MPa ---- 600 NMm' ad C----0.6(assumed)

d, -- 128.08 mm, b, = 96.08 mm amlA --256.17 mm

.. Prom equafion(1), we have F -- x(128.08)4 (600) 256.17 --0.6

2•‘ draw -40°Z» reductlon

d₂ - 76.84 mm ; Its= 194.32 and A= 128.08 mm

NoR that D « 256.17 mm. In 2* dmw, the c@ diameter will be 128.08 mm wfiich upon
40Po reduction
will &reduced& 76.84 mm dianaer.

'. From equation(1), we have F -- @76.84) 4(600)

28A08 --o.s -
’664

618 • 10'

3^ draw -2.4eZ«reducdon
d; -- 75 mm ; âJ= 200 aadA= 76.84 mm

. . From equation(l), we &ve f• = n(75) 4 (6H)

/, - 240 A/V
76&1 --0A =240 • 10'
75

l* draw 50%
2^ daw 40%
3° dxaw 2.4%

Meet Metal Forming

21J
Problem 11 A shell of 80 mm diameter azld 250 mm helght is to be drawn out of
deep drawing
quality steel of 2.5 mm thickness. Determine the number of draws and the inldal
blaak dlameter.
Also calculate the dmwing force if eg= 300 MPa.
Solution :
shell or cup diameter = d -- 80 mm
cup height = â ---250 mm she£ thickness › = 2.5 mm
a, --- 3D0MPo 300N/m»Y
To find Blaak diameter(N)
w.kt. Blaak diamter D - + 4d

= 80 +4(80)2 0 =293.93zm
6 - 293.93 mm
›i›« - z - ;J22' -67 is • i@«
To determlne the number of draws
Let the l• draw have 50% reduction onthe blaok diameter!D)

w.k.t. % reduction P, ---

0.5 =
D -- d, D
293.93-- d,
293.93
. . d, --- 146.96 mm & •1, = 16.96 > 10' mm2
y-y (6785-16.96)x10’

w.k.t. height h, ----

•a, x(t46.96)
= 110.22
.'. h, -- I l0£2mrt Let the 2 draw have a 40% reducaon
d;
w.Lt. P2 =

0.4 = 146.96 -- d2
146.96
. . d -- 88.17 mm & d0= 6.1 10• mm'

216
Manufacturing Process-

w.k.t. â₂ =
A- A₂ (67.85— 6.1) x 10
WJ ' 88.17)

= 222.92 mv ' •
h2 - 222.92 rim
It is clearthatthe 2^ draw yields a diameter 88.17 mm which is very close to ie
iequind shels‘ 80
mm. Hence the 3°dnw can bring the work to the required size.
To determine % reduction in the 3* draw

w.k.t. Ph -
dz d3
d2
88.17 —80 88.17

= 0.092 100
P3 = 9.2%
Hence a reduction of9.2% is sufficient in the 3°draw to obtaia ie desir& cup
demensions. To
calculate drawing force (

D
w k.t. dmwing force F —— r d t a j;J
Let constant C ——0.6

.!. F — (80) (2.5) (300)

drawing force F —— 579 kN

293.93 -0.6 80
Note A rough estimation can be made regarding the number of draws required by
usirig
e9vinaon given below.
No. of draws = h
d
where h -- heightofcup
d - diameter ofcup
Problem 11 Estimate the LDR for steel sheet subjected to deep drawing using
the
following data.
Elongation in length - 25%
Decrease izs widtb = 15%+
Strain ratio (R) —+ LDR
2 —+ 2J
3 —+ 3.0

Sheet Metal Forming

Solution : w.k.t. in deep drawing, the normalanisotropy is measured using the

equation

ln "’
two o
where W₀ & Share the initial & final width, and L₀ & L are the initial & final
lengths

w.k.t. % elongation =
217

0.25

0.25 =
— l or
= 1.25

w.k.t. % reduction in width

0 " ’f

’0

0.15 — 1 —
’O

’0

Now equation (1) becomes, fi =

0.85
ln '0.85) 0.162
In(0.85 x 1.25) * 0.06
A = 2.7
The value off = 2.7 lies in between the given strain ratio 2 & 3 (Refer data in
problem)
Strain ratio (fi) LDR

2 2.5
2.7 ?
3 3.0

218

Byinterpolation,we hai‘e x -25 _ 2.7 -2

3.0—2J * 3-2’
= 2.85
-. Limiting drawipg ratio = LDR = 2.85

EXERCISE PROBLEMS
1. Blanlu of 50 mm dia. are to be punched out of 2 mm thick steel shed. The &ge (
clearancebetweenthe punch and die is 5% ofsheet thicAess. Determine\he dimensions
punch and die
and the punch force, ifcutting resistance ofthematerialis equal to 300 NHH,
Ans: Die size= 50 mm, punchsize49.8 nm; punch force= 94.2
2. A steelwasherof36 mm outerdiameterand 20 mm insidediameteristobenudefiom 1.2
thick sheet in
oneoperation ktheshear stress is 400 Num’, determinetbemaximump force necessary to
blarik and
punch the washer ifboth punches operate at & same time.

3. Two holes, one 4 m sqwe and another 6 cm diameterareto be cut in ametaGc

sheet3 nzb thicL If
shear strength of the material is 2500 k /cm°, determine ie cutting brce

Brat : Perimeter P — 2 [a + b) +uD

Ans: Cutting fo«e= F— 256.4 W; stripping force= 20.9 2Y
4. A steel washer of44 mm outer diameteraad 22 mm inner hole diameter is 2 mm
tbicL ktls
maxmum shear saess is 405 N/mm• and pwcentage pcnetrafion is 24, calcuhza«s
dOe.

5. A cup shaped component of diameter 26 mm and height 75 mm is to be drawn out of

deep . drawing
quality steel of 1.2 mm thickness. Determine the number of draws and the initial
blankdiameter.
Ans: No. ofdraws= 3 (50%, 40%, aad 5.8%) ; Blank diameter D —- 92 mia

Uriit —.8 ” ." ” ’.

g’. J OO, UCTIQN’ TO #OW.D,E. 8 :

’’ ,
aatcfiaL The.detai1softbeprocessaredeacni›e-db9 ,,

ygm ,tm various octbods availgbta Dr production efpawders, *¥P*^*!**8 ^!

**^’*^'**’”“”,

Tuhdlsh

F@ut;e 8.1 Atoaiizañ**n

mo”lten tnetal
" form

<-<•saa» a»am»=xe••«=•mn ‹w«›en‹»qww ‹sg,@

= • ^'>%'*>*>****dññ&pmAoaAdit&oa‹3›msiarw Btn«1itgamswt,mu
attés a,ca<,d a,e +a/t/»a.1,wmAai»aaaa••»•• duauuuaa°sm
aa¥<t•sgasmsattaag••&R,a3a9at#aaBs6\6as'a&aA2^**^***PB***

proportional to the particle size, smaller particles cân be produced using water
atomization. Tlié
smaller the particles, the more homogeneous themicrostructure of the part will be.
8.2.2 Crushing & Mimng
Cruslung & Milling methods are used for brittlematerials. Jaw crushers, stamping
mills, ballinil]a
are used to break downlemetals by crushing and impaa as shown in figure 8.3.
mtially, gyrato;y
crushers are used to crush brittlemetals to small sizes as shown in figure 8.3 (a).
In order to
obtaia fine powder particles, tbemetal particles are fractured by impact in a ball
mill as shown in
figii&
8.3 (b). Aball mill is a special shaped container holding a quantityofballs which
are freetotumbk
particles to a smaller size.

Crusher
wheels
powder

(a) Crushing
Drive roller

Figure 8.3 Crushing and milling equipments

8.2.3 Chemical
The production oféon, copper, Nngsten, and molybdenum powders from theérespntive
oxides through
chemical reduction method has been considered to kaconvenient,economica1, and
Oexibk

Fe₃ 04 + 2 C —+ 2 COC + 3 re

in a stream of hydrogen gas according to the reaction:

O + 2 Cu
Chemical reduction method yields yields extremely fine powden with irregularly
shap& pmcles,

Powder Meiallur y & High Energy Rate Formi‘ng

.8.2.4 El<trfilyKc Doposidoé

Electrolyñ; deposition;iiethodis cominonly used for lemaauñcture ofironaad copper
powd«s for
special applicafions. Eloctryl iñ powdqrs are pnxluced ,based s» the
princ@R. used
elsct'°pla&g Y?'<*°o*"'*,°°*changpt»ord»?oprodwealwsepowdrrydepospzat1,athgg a
smoothadherent1ysoli;i.&jer.
>*P°=^ r. «*sP«P/°esa'sslased»,a°odes=aetaniofe1ectroIpe,w«eaiw»imimpjgg,
^**é!^’*^*“*•*•”*!**"^!***^*!Y!*.**a•!^sé**od¥. WhmaDC ct!
rréntisj¿assed.thro«@&dacth¥ytc,”
deposited on cathode. The
*$thode is favoured bylow métal ion coficent;ation i;'tbcelegpgjyjg, high.acg
gppgp;ggj¿g,;ggJ
high.cathode S'irrent dpasJty. ?21e cat;hod•.p&ks’are,taken out from e;ectro1yte
taak aigl tJu.
dePos$ed. P°^'>''*'wP°< oS. Ttiepowdcriswashed‹,1«•dandpulnrizpdtoproduceppwder
O[j*°d**%£&°@e-Jbc Po»Ar is Satlier Subjected>’heat:treatmentn order tq removes"

8.2.5 5bott1ag.” -” - :
-
- ”-
>**•°'•***•t=*"••*'°»°nf«4te»>etalisp‹»=edileovghavn«tingsiev»(ororia,e)»ogir
.orneutral-a@ospherc and then allowedtq fall ’mF&@. Ts•siream
éfmo1ted.inetalilisiigegfW
«tod«›sl•is añd solidifia P°'fi?}*^ during 'i* **’U k* â*.
St»11e.paitislg»aigp
so{idifyiawaterinto featberysha p,
8.2.6 k!ondeusañou -’ -’ : ’---’
.>this«etbod, maahareboiIedoreyapomt&topnxkicemeialygpgg,g,pg@g,ggg,gggjg,ggJ
powderl9ypron the ‹holing all, whicha«tbC’nremovedcontiauouslybya scmper. Tbepr
$
isappJcabletovolatilemetahsuchas ziac,:piagnesi»«i.and’cadmiu›n,
.a3 citsancnaisncsorurr,u..powoER’
P'°P°'t'ss-° .P ’obtain;:d
0°mpow;lermetatlwgytechnittuedepmd.ontheguaj;yoftbe
metal powders pmduq&. Following * few important « mimics
ofmetalpowders:

(a) PartlcIe Shage„ . ’

:
Thesiy;peofthep°^d°'P°'ñ«les.°'*r>°=&^.*P>* '=t.°48uFr.,andfip«lñtic,.Thegaitick
shape„in0uerices 4e-"flow charaqtqri¿ties ofpowders.Spnericalpartic1es ha›e é icéli
;iri

Powderpartic&iaggfifinzi0.1 to l0mmiienn &sizeaiataenbe‹»eeññiyoo«n&d,

1mce&pgckingeflicieicy;tteag›nin&density malf»élporoai?gofdcjr'xlnct
t& <•=<*>
F£mmleis&abi1ityof&I›on&rtofk'wnadi1yuatc'xxhea'a'tlnmouktcovity,

Apparent dmsity is
'wa»
•'u»n•it a=ct•ua•l v•oi=mn"n•fi"tte«d-b•y amt&•i ••"••h••a'•d»n.«’flu
density & irregu&r shaped particles wR be lo»cr(due to igefluigriT)
tlantlnt A&u
pspgjmgicgalgpgqltigcjgp;
Agspsig„b„,t„1gm,zpwa„b„c,agrotmti+miavolianetMtoccnia+npresséqai44&
‹s»-›e
,

&4 COC A @I4\NBING POWBBBS

zn
ahoea%figate8.4. Iata1caasai«a8aiaBbd%ttwpoo¥%rpaticIast<5aczaJ¥%gae•bre
Scraw

A5 COMPA€ ING )DERBALPOVMM S

227

Atsinteripgtempeiature,&ecoppñrmeloalxt tbendifliisa iatothe iroa-

powderparticlescrnating swelling.
Referfigure 8.6(b).’ By caréful Election ofcdppercont it is p6ssibleto
bakizicethis’
swelling,againstthenatuial shrinkage,o the ironpowderskeletonand
provideamaterialthadtes
,not change in,dimensions at all during sint'ering. Refer-figure,8.6,(c)., The
copper ad‘dniofi
also
p»«des i;useful-sofid«o}utionstreogtbenin$efféct. “
Note Tbeefléctofsinteringwithgspecttotbemechanismsfiiscussad,a0oncan&bestuixleisood

Necks

- Fl%i:8iJ S.intering mechanism

boundary

1i.7 ISOST@TIC PRESSING (COMPACTION)

Apart frñm the Diepressingmei addiscussed ia,secdon8.5, there ate several
alternative methods'
to.foñnpérts%mpowderiJa'terial.,Ammg;bese, gostan*prassinanthewidelyused:aiahodto.
produce
large.,size parB:.with uahmited capafitlity for coinphx shapes and.geometric
feattifen. However,
isontatic.jiressingisapplicableoalyio.smallpnxlgctionquamitiuaiglatsoaon@mdtsxl
coiupandtootber
pn›ceuadue&,slow.speeéaildexpendabletooliig, Tbepnxluctigttgbi%ie

bend $ h pie
$1 n°°.q°° il7â°d.°i‘°°tit
a) Cold Isostatie ’Pressing”(CIP}
in:o rto comp& e Preaatge é app $
'?g°éikiii/i37fik/âi" "°'”" ' °
.Cold isostatic, pressing is a powder compaction method.§erforméd at'ioom
temperahi;e. Refer
figure 8,.8. The process makes use ofa’f1exible,mould made frotñ a elastomer
math.suth as'
uretlxine, rubber, o:jiolyviny1cUorids. Thepxsswcfwoompacting ihemetalpowdera
applied through a
fluiñ, us«allysil or water, and1epressurevari« from 4&MPeto 10002dRs.
In opemtion, tbemetal powders are pow& into a.0exibR mould
whichissealediaaliighjimssere
container., The shape, ofthe mould, is similar to,that of a» desired product.
Hydrau?c p/regsiire
(pressure ofAefluid) isexertodovértheentireoutsidc,surface ofihqmouldcâusing,it
to}iréssand form ie
pouider into ,the correct geometry. The pressure exerted by thq,f1uid ov> the
élitire

surface of the mould provides uniform compaction of the powder and uniform density
within thc
compacted part. There are two types of cold isostatic pressing: wet bag and dry
flag method.
In the wet bag method the mold is removed and refilled after each pressure cycle.
This method is
suitable for compaction oflarge cxl complicated parts. While in the dry bag
method, the mold is an
integral part ofthe container. The dry bag method is used for compaction of simple
and small size P
-

Pressurization source

Container

Pressure acting on

Figure 8.8 Cold isostatic pressing

Cold isostatic technique is only used for semi-fabricated products such as bars,
billds, sheet,
aixl roughly shaped components, all of which require considerable secondary
operations to produce
tfn final, accurately dimensioned component. Again, at economical workingpressures,
products âre
not fully dense and usually need additional working such as ix›t extrusion, hot
rolling‹r forging
to fiillydensitythematerial. Further, the partmust be sintered after removal from
the mold.
b) Hot Isostatic Pressing (HIP)
Hot isostatic pressing combines pressing(high pressure) and sintering(high
temperature) operations,
causing consolidationofpowder particles, eliminating voids and pores, and hence
forming a sound
high strength component Figure 8.9 illustrates the hot isostatic pressing method.
The equipment used in hot isostatic pressing is a rigid steel container (die) in
which the metal
powder is placed. The container is evacuated, and the powder is gassed-out to
avoid contaminaion
ofthe powdermaterial by any residual gas during the consolidation stage. The
containeris sealed,
then heated to about 480’ to I l20°C, and subjected to isostatic pressure(100 MPa)
that is
sufficient to plastically deform the powder particles. Argon gas is used as the
fluid to pressurize
the mould and conform the part inside it. Simultaneous application of all around
pressure and
temperature

neat ””••=•
0—+„

&8 PUNISHING OPERNfIONS OP2N2WDER METAkZ*URGY PAR¥B

• Mnchfnizg izienhm nxaeeipg unnatural @ izmzu ofmitabL cgf&g eadgt inqmt

230

• Reat treatment involves controlled heating and cooling ofthe powdered component
inwda
toalteritsphysicaland/ormechanicalpioperties,without changing
theshapeofthecomponent Wear
resistance, strength and hardness caa be altered as desired.
• Plating involves coating the surface of the compollent with a metal in order to
impart a
finishing appearanceonthecomponent,protect from corrosion, or improveelectrical
conductivity ot the
component.

8.9 ADVANTAGES & DISADVANTAGES OF POWDER METALLURGY

Following are a few advantages and disadvantages ofpowder metallurgy process.
Advantages
a) Efficient(nearly 95 %) material utilization.
b) Parts from high refractory metals can be produced with less difficulty and
cost.
c) Components produced are clean and ready for use.
d) Near-net shape components can be produced. Good surface finish and close
toleruice can be
achieved. There is usually no need for subsequent machining or finishing
operation.
e) High production rates are possible.
9 %deiangeofpropertiessuch as density,
porosityandparticlesizecaabeobtainedforparticuiar
applicabons.
g) The process facilitates mixing ofboth metallic and non-metallic powders to give
products of
spxial characteristics.
h) Porous parts can be produceil that could not be made e&ciently byanyoler
process.
i) Skilled labour is not a requirement.
Disadvantages
a) Metal powders used are very costly.
b) Storing metal powders offer great difficulties because of possibility of fire
and explosion
hazards. Aho deteriomtion ofpowder may take phce during long storage
c) Parts manufactured bythis process have poor ductility.
d) Sintering of low melting point powders like lead, zinc, tin etc., offer thermal
difficulties,
as most oxides of these metals cannot be reduced at temperatures belowleé melting
point.
8.10 APPLICATIONS OF POWDER METALLURGV

Powdermetallurgytechniqueis used for pnxlucing components for various applications.

them are listed
below.
a) SeF-lubricating bearings and filers, tubings and pipings, etc.
b) Friction materials like clutch liners and brake bands.
A few of

c) Gears'and Pamp.roprs’
231
d) Electrical copiacts andresistanceweldinJ’electrodesareyiade by
powdermetalkagyteclviiqpe.
.Acombination ofcopper, silver and a'refractorymetal-liketungsten.molyHemimandeic&l
provides ie
xquired charactensacs like wen resx&b-refiactory, andelectricalcon0uctivity.

bytliis pixiess.’ .
’
f) Cutting toob, wée drawing dies and deep drawing dies made from-tungsten,
titanim arid
molybdenuiy areproduco;1 effi0ie tly@poivder r°etalkngyt«hiiique,
@ Cwently,.titanium implants are made p'rimarily by'forging, casting, rolliag aad
zgacbinlgg, gg
qazid c involv& in ,thue processes has made powder

8 11 £fIGR /ENERGY -RATE FORMING (RERF)

High ietgy orrnJg, itbb qted asIf , '+'
g P
in fbich> â aifioqotof
euergy'is applied to the work material,for a very short intenal of time. Fencing
ofAe work
,material tothedgsired shape maytake palace iajust a few,thousandtbs ofa secoaA
Sii«e he parts
-are i"om& at ajapid mte, tfle process x also called as jigb wlocity forming
pn›ce6s.
Need for &ERF '. ’ ’'

**>kba»rsrme**L&ismethoA.tb«workmetalnshapedia.mi'xese«xxh,bym'%iaofplrssum
generated.,bythes';ddenapplisauonofla'8eamouats ofm»ey. Tbewerkmetal,,mmps:casmn
slammed against
the die and'shapedso rapidl'ythatthere is notendencyfortln;hapedmaterial to
return backtoitsoriginalshape. The iequiredpressurefor,defoimingthework
is,generated
fiom-anyofle foMowing metboA-:
a) d<onatingexplosives -
b) releasing compressedgases
c) dischargingpowerfulelectricalspaiks, or
d) el«tromagneticei1ergy. ’ -
Classificadon of HERF

232

a) Explosive forming
b) Electro-hydrauhc forming
c) Electromagnetic forming
d) Pneumatic Mechanical high velocity forming

ManuJâcturing Process -111

8.12 ADVANTAGES & DISADVANTAGES OF HERF
Following are a few advantages and disadvantages of high energy rate forming
methods.
Advantages
a) Production rates are higher, as parts are made at a rapid rate.
b) Hard and difficult-to-form metals can be easily shaped with HERF.
c) Severe deformation results in better grain refinement in some metals.
d) Spring back effect onthe material is negligible.
e) Low tool cost and inexpensive machinery leads to low production cost.
f) Low scrap rate.
g) Complex shapes can be easily formed compared to any other manufacturing
process.
h) The desired shape and size are obtained in one stmke (or step) ofthe
operation thereby
eliminating intermediate forming and pre-forming steps.
i) Suitable fora range ofproduction volume such as small numbers, batches, or mass
production.
Disadvantages
a) Skilled personnelare requinxl fhxn design to execution stage.
b) The process is not suitable for highly brittle materials
c) Sourceofenergyrequinxl for deformation (chemical explosive or electrical)must
be handl& club
Mentalregulations, procedures, and safety norms need to be followed.
d) Die design is complex as high energy rates and shocks are involved during
operate
e) Controlling the application ofenergy is critical as it may crack the die or
work material.

8.13 APPLICATIONS OF MRF

A few applications ofhigh energy rate forming are listed below.
a) Forging supa-alloys,refractoryalloys, titanium alloys, etc.
b) In ship building, to form large plates and other parts.
c) Radar dishes
d) Rocket nozzle inserts.
e) Turbine blades and wheels

j C;addiggoftwo &gcptatmofdissixoilarm*aA et•.

8.14 EXPLOSIYE FORMING

Explosive forming isametalworkiag technique in wbichanexplosivecharge a used

insteadofa

**!80^*^BY*^^***’*’ '^**** ***^**

aBtaia tbcdasired sbaP^ Tie tocatiai oftbe explosive ^*!*^*P*^* to ^""’*••*a!
8*•B*

Dstatal-o&ayé=a1•q&ezp&ive***%B***!**^+^*!***’^**’d1staz*ceawqy6eztttmwat$****t'

8.14.1 EzpktséveFonabtgaa6•8*******-****'I*-*^**** ***)””‘**’4**’

heatigg of th entrapped air ñany.

H = Hydrostatic head S = Star•ImN distance

Fuaa plug

234

A definite quantity of explosive material is placed the watér medium at a

defifiite stand'
distariñe from Ie work material: The,stand-off‹ stanm,depeids on the size of
%e”work, ;
typeofwork,maferia1 bñing’,de%rmed. ,On'detonatioii ofleeiplosive chargq apréssurep
shockwave)
ofveryhighiatensitynproducedalong wA.butibles ofhot gaseous detonafiou
The gas bubbles expand spherically and then colapse, wMe 1e,shwk waves travels
water and delivers
great energytotbe work metal,therebydefonning it instantaneously to the cavity.

Process varlables . ’’
. -’ "",
; . .
,
A few variables that a&ect,the opemtion ofthe process are listed below.
a) T$pe snd amount,oJexptosive usnd
’.Expl::siws,thnare.caJiable;ofpieducii;$‘high;inssuies.lih:TiTr.(trin%;toluan),PEw
"
thritoltetrartitrate), RDX(cyclo-
nimethylene@ngrpmiac)and.aitroglycerinepreooarnioaty
The amount of explosive used, depends onthe amount oJeaergy mquired, which is based
work melal thickness aad type,ofworkmetal used.

,Staad-oPdistaacerefws to„1e distance between the location ofexplosive and the work
'
and‘should be as minimm as possible.‘ Hownerthe distance must not be,too.small
as:it, result in
heavy deformation and thinning'ofthe worQiece. Smal stand=offs are.used,’br
draripg, g°d 1ngestapd-oils for shallow drawipg.
Ge°eraliystaad«B»pioportioaala@dggietg, of@e work
metal.- -
i.e,’stand-off(S)’= D, when work,dlameter‘(D) /o up'to O.? m, aad
5r 0.5 D when work diameter (D) is mqre,thaa0.7»i.
c) Dydrosta c head
--
The hydrosta8c head (H) in explosive forming is defined as, the
vertical,distance’betwccntbg.
explosivechargeandtbe«atersJace. Rekr figare 8.1,0.
Thehjdrostaticheadbasaoonsideeabb
ePect’oniheamount ofdefomañoqAatcaabe’obtained from a.given amount
ofexplosivechatge. Generally,
H’- 2S, suiserc fir Stand-oifdistance. ’

›Sdvantages ’’ - ’-’ ’’
*
a) Shock waves are efficientlytransmitted through»aterand hence'the energy
for'deforaifiig the
work metal-iseffectiwlyuGiz&.. “
b) Less,noise as water muffles thesoundofcxplosion.,
c) .Less probabilityofdamageto’woAas the detonation,energyis transmitted
uniformlythnnigh

^! , P‹n der Metallurgy,& High Energy Rate Forming

. izaaaa »i
.a) Optimum staad-osdistanceisesmntial for pwperforrgiag operation.’
b) Vacuum is essefifialand hence it addsso 4e production cost,
c) Dies must be larger, and thickwto withstand sh0cks ofthe detonat& charge.
d)’ Not suitable for sniall aadthin e•orks.
’
e) Requinxl carefulhaadling pfexplosives. ’ -
.
8.14.2’ -Explosive Formiog «sing C;;ntact(Cenflzied) TechAque -
Figure 8.11 shows the explosive forming meAod ia a contact operation mode.
The,exploaiw
charge inthe,?orm ofa cartridge is’held a direct contaa w eloa° proximitywithle
ror2aict&
,On detñnation-of the explosiw charge, the prassun pulse or shock vavN produced.
fumes work metal
aio.aewnlhnftl»onldfonoi›gt1»psrr n•pessuresulsopn›d«»déa4iW
coatactwiGtlaworkm‹@landlw;icc&poleigy
is dJmctlyappliedoa workwitbot88gy
medium. Since.tfic detimatimtakos phco iaa confipcdsystem,extrema9‘@h presatgm,,
(uPS
30,0002dPo)maybuildeptbcrnbyzecessitatiggsaAtj‹consideigtit?
u. ,T1w&fni1aiuwoaig0igcaA
caisemw›atiustnhaiqueoffonuaig,?tu;›nxmsumaaityi»edmbvlsinemd 0«eso/totm..

Figure.’8.11 Explosivefonniagusingcootmttechaique
Advantages
’’
a) Since explosive é placedincloxproximi9tfitbe \vorkmetd,
m4igyisñti1i2tdc&cfivñ1y. Tboio'is-iio
loss incnpgy« air /'x$@ & is%the case,ofTleml-offtHlmiqA-.
$) Low$ggp¿qpggy gpyg$¿pgqtoqggpqyppgjgq$qg
- , ,
c) , Suitable f«manuActuring-prototype,parta. ’
.

Discha,rge switch

a) Nasuitable for large sizcparts.

b) Hot suitabk fw materials tanrizig hw ductilityor Aving critical impms vnkcity
kaa t1mt

c) La,g«s»e‹apga‹xsar«q«ii»dram«igya»iagnwi›i«hi»rwsoWorn»a%‹%i
e) Vacuum is required ifitln die

8.16 ELE O6MAGNE77CFG]MMNG

pmcess f‹ir electricalJy ooixlucfive metala, nest oxnmooty copper and “

when a currea &ws tbnnigb a ooixluctipg material. say a cok a magmtic 0e!d n
>t&fifmt

coil, the coils magnetic fie$ is disrupted and eddy curreGAsare gnneisted
@t1g,gfig@s§@ .7ic

o co$ i£sa it there ts l%Sti»ebetw coil

iâat x fixed and the thia a+etal is placed mar a die, tlwi the rg0°I1ii;8
forces cailsm &
diinnWtR colbq›seigtotbedig, coixformig$&t1uosdinirsoft1mdie‹xvky.
FWnoaiaglWérWnkgW&
onfBeabovepiiwipk. ’ ” ”
QFESTION BANK

,Illtrodtte’tion IN Metal Vo I i g
1.,°Explaig‘brieflyhow/ihefi!fferentmctal›io;l:i''gprcicessesare
élassifiedonthebasisoffice appled.
Draw necessary Skdches.
2. .Gin a detailed cl8sSJ£8hOfi,ofmetalror£ing p«msses.
3. Classifyandeg›lainthefprmiagprpc»ses.
4. Defiinwrougbl,p clearly.
s. Ixaa°r''ia°"iearirb»'*e*''*'°uab'P'°°"•'°•°*°••tP'°'*•*- *'**°* *""•! *°'°
p.’ What‘u refining.’Exp1aintb•st;ucture ofwrou.J;ht productobtai@d’b./hot oqiz@
7. plain,briedytheeifect ofhot working and cold worki›ig.-What doyosl
mg@buy@et‹@i
8. Diflérmtiat•t›et«‹g«coldworkingand ho; yorking.

10. State&advalitagw W, °' ^ g8°*°°*°°*

06ME73 Dec IJ —5’m
jq ,ggpjg;ptjq,aliag:&atnres:ofagtalfengirgpns:mscs.akng:witbtheadvQa8»j@J>°'*'>"
^

i2. o»ssa»advmtagesa»diimioaio»o?metalworkin8o*pr*›*$=Pn›du'**=P"*°•••°-
ME64 Jan 10 —,5,m
13. Explain the cooceptoftFn •i•ms and tiues?ain
73 Jan
10- 3Zfl jq. periw,the,exprmsions,for’iruestress„and true strain.
hOé4
July07—,5 m
15. &fiaetruestress and true stFdlfl,.. t a›naq ayantagepofusing
these’.onreigineerin.g
stress and st n-
J 10 -5 m
16. what,a're1a0onsbipbetwee»ensiae%*$&,°ai *•*°'** *'***'* *•• 7^
'°

1?.
nominalstiainwdtmestraiu.. ’ M
ui> 6
m

18. ’Def+in clen9trus m°°°andi'**

Definetbetermsused clearly. Derive p
igjgg„ge,›gsoms-cenventiona1stiain<onve'aie''alstrmsa' i'*e •*'%*-'%•'"'<"'<*°•'°
ME6$JeoolO-l0m
19. Obtain an»pression fmpiincipal:stresses aDd SHRSG of;ibiaxi stress
elnmnnl-
ME64’ Jan 09- fi m
.21. what a no> soess. Nam« the a‹si«xis to é‹'«x'''*'° 'I'° ***^ °"°°°-
V'*'*• ••›'•°
gtgpgg
06ME73 Dmj:1—7’->

,24.. Explain ciearlylhetwoimpOrtalJt@1d’criteria used”mroetalworkipgpio;:ess.

06ME73 July ll r8 m
Explain(a) Tnsca’s yield criterion,&(bJVoa-misesyieldcriteries 06ME73 Doc tti—
lfiU B:
ExplainTreka’yioldcriteri‹xL,
ME64 Julyo=6 m 27.

29. DefineTmscaafidVig-inisesyieldcriteria and e8tablishtlur

lati,gabipbetwémtgtsilceel
slgar yield stress* Considertbeyieldipg ooxirsundaunia=<k*'*<*>%8*'<,."'<<P'°*
-- ..
.’ , . 7
3§. Derivearehtoeshp betweentens£e peld stres? j•;ksbearpc!d stressk .
.
ME6$ /m07 -,S m
31. ExplaiziwithasimpRsketchwbatumea°t@ptaae***°i,°°"'> "*
rnit-2 Ea«t ofnram•«rs ln Met'•l, W•r1dn8 >°••°°

2. :D»cusi‘tboetfectofvarioussara'°°te'°°°'**'<worki°gp;'mss. }
*"**
’- 3. ..Write asfiortnote on.ePect ofRmpeiature.in metal working pn›ceas. MBd4
July,07r 5m

s. ’Exp%itfie pJIi'cn ofstrai° rate iametal working. ’

’- p. Explaiaaeékectofthe&Awizigpametal woiAin8piocessse
(:) st,an«t« ;ii) temperature osME73 Dn
1Ol0m

.8,’ Explaiatheeeecto;tbek›lowiog«meai›iorkinapn›sess.’
(i) friction and.lbbricatio (ii) ’strainrat¿ p
slept
JYyo8 —6m

9i. Explaintheeffect ofthe following on metal working processes.

(i) temperature, (ii) fricñonand lubrication
0,6ME73, Jan I
10o J0.. .State aad Explain Coulombs friction law:
MBA
July09-5& 11.,’List any five important functions ofa,lubricant used in metal
working processes.

12. What'is hydrostatic pressure in metalivorking., Explain.

15. Explain wit a neat,sketch the,hydrostaticpréssure,in metal Working.&ME73
Dec 1,0-#g
14. What is Jiy‹i;ostatic ’pressure. Explain thé importance in achieving i
successful fen igg
operation without fraéture.
15.’ Discuss the concept'ofdeforñlaiionzoñe geoinetryin metal working.06ME7J Dec
10-5a
16. Write,anofe,on’wortabilityofmaterials.
17. Defuie workability of,a materid. Wi1the.help ofsuitable diagram
explain’brieftybow i@
residual stresses are formed in metal,rorkingprocesses. ME64 Ju1y03-2+2+4=
8fi
18. Comment on(a) deformatioiizone geome@Q) rssid«alsoesses,in wrought products.

19. ,Showwith'a neat sketch'the defomationzone geometry ofle foJowing:

(a) Tube:drawing (b) Rolling
20. Djxusstheoccurrenceand eBect ofresidual s&sses onproducts obtain& by metal
workigg,

21. Discusstbefactors affecting ontemperatureinhot working.

State théadvanbi$m
§ ofilot»orking,over cold'working.
22. Listthemethods ofmetal deforming analysis. Briedy,explainany2 ofthem.

23. Define fonnabilityofmaterials. Discxs any one method to detennine formability.

24. Discuss ia brief the diRerent methedsused for,analysis of metal

deforniatimproces8,

Unit= 3 Forg¥g
1. Define forgingand;explain’differentforgingéquipmñnWwith’schematicdmwing.

2. Withaneat sketchmplaintwo forging,equipmems.

3. Wtth neat skeeh explain the wrirking of(a) boaifi-drop hammer and Q) steam
hammer

4. Comparc,hydraiilic, préss and meclianical press,with respect to

differiintfeatureiand salient
characteristics. ’
ME64 July06—4 m
5. A bent lever is to be formed by drop forging in multiple number,ofpasses. m4
tbq heQ of
suitable sketches, explain 4e different stages ofopemtion. ’ ME64
July06—6,m
,6. Deduce ie expression for forging pressw and load in open die forging by,shb
analysis
(oonsideriogsliding @ction). ’
. MEâ4
Jaa07—l0m
7.- What is ie significance of slab analysis. Explain ie steps innlved init.
’
’’ 06ME73 Jaa 10 —6 m
,8. /Deduce the ,expression for forging prexu< aad load ia open die forgipg
by,slab analysis
-+%gsuigbleassumptions.
0dME73”I7ec
1fL-l0m
. , „,. . . . .
, ..
, , .
9. Deri*ean pxpxssipn %* 8P'm*!^° °*%'*%'°8 *
fi
sliding occurn, at iakmce). Heiiñe, draw the frictiomlfill‘aad ,explain brie0y the
effkct of
diffemntpaiama«nonFrictio>xik .E64,Jidy05-
5+5-10%
10. Usigg slab method, denve ân expression forfor$ipg load ua$erslidipg agl
mckixg-frictiott
Descn2•• the ,Atribuaon,ofprgsigenwrtbew:fitboftaeakiP’undwcoinderation.
’.ME64 Jan 10 —8ai
l’1. Ui'ataretbeaâsunipaons madewhileaiAyzing;fercoduripgffirgiilg. I@rive the
expmssipgs‘
*•rf<si»ssr»s•w«•*l°°‘’°e«•’•*¥?<&gbrsiab»at«»:(*m%«»«»s <iol»mo).
Hence.find meaaforging piessiire(i) with Coulimb friction at 4e iiiterfâce,(ii) wit
Instant
friction factorat the interface. ’ .
ME64 Jaa08 — 12 m
12. ExplaiafrictioriGconcept and the factors affectiqg it in forging. 0dME73
July 10—5 m
13. Discueé the concept of frictioi % anfi derive ân expression for a maximum
pressure for
*!cking‘fri@ond‘uring brgingprrcess. .
MS64 Jaa09 y-8 m

1’7. List the different, design parameters ia desi’gning,forging dies. ’Hence

explain briefly the
d'ifferentsteps in-mlculatipn ofiaitial mgotsize foyforg'ing. - ME64
July-06—? m
18. Explainclearlyd'e des'gnparameters in)closeddieforging, u^ingcl hJ
:i:.— l0m.
19. Wnteanoteoadowlinesinforging. , -
MEN
Julyo—Sin
,20. Explaiadiffereat,typesoffoigingdefecia. ’ .
idE64.Juiy07-6m
i!l., :Discusa’thefol1owingiabrgingpn›cess’ (a) frictionfiill @)forgingdefmta-
(c)gataigl&w
li°es. ’
-.
06ME73 Dec 11r 8m

Romng
1. ’Dcfingthee»„, slab,,blonni,billetanda«v•o%»apr, toroJling, ME64 July09-6ni
2."With,iieat:sketcbx desin@, thefii&e;p;ttypéso-rrollingaiillsand '.° ^°*"'i’ "
“
ME64“Jan 10-5ai
3. Wbataretbe salient feanires ofhot rnlled,pfoducc. List the
liaiitatioasofhotrollipgi

4. Explairitypicalarnnigefilentsofrolls $orrollipg mills.

j, Witb,ga;sknc% t„pb,;„,jig‹gea;typesofrolling’mill,anangemsna. ME64’Juiyti7-
l.Oia
6. Explainplanebiryr *’ .
7. Explaiutfieciust«wdpldfgjtafylDllipg millwitbaoeatske;ck @â64. Jan09-
8 m )
& WiAtheheipofneatsketGhm, brie0y»p1aiafow-stlnid,;x›ntiauousinillandpl
n J£
ME64 July 05-2+2—4 m - ]
9. Eapii,in the‘s›i1oYi»a»lli»a«ii£s.’ (a)''r hich '**,.OJ* <"'*'< (*)
*'^'>°"'*
06ME73 -Dec 11 —-8 m

10. gxpix. '°w.'tban°at,i1'°i'ai°f».llina..''q(')›°''' .

'°?!.:’*„,;g- .(* :raixt°°'°j;g „,;g

11. Wbatis ioñseparatipgforce. ,Explainclearly its influence onmgtal

workiagprocesa.

12. whai»rouseparatingti›rce. hxpiainclenty. Also»s1ainwf/camb•rwitb°°"*°*•*•>°-

13.’ Explaiiitheeffect ofstripteNioñ-onthe distributiofiofroPpreniure., MR64 Jan
07-7 m
;4. Explnnbrieflythe,eSect,ofroMcamber& rol d8ttering. ’Wbat.ix Merchant

15. Describetbe.effect offrontand,backiensionon >lling load. ME64

July 08 -5 a
1,6. Discuss thee¥ect ofbacka»d aoateosioos"on «Jl presswe,
17. Withaneat,sketch,explainne t po t„oo* t specific roll P
-
ME64, July 09-6 m
18. Briefly explain the phenomenonbf the $ffect of back tension arid front
ME68’ Ju!y.l0r 5 m
1.9. withthein8ofsuiablé,ske;ch,shoythediffem*,P"='**°'*of'oil%.
ofNeutral poiat, What is the

.- M&eoominen8 onthiscoia1i%n -
ME6'6 £uly’05-J+2-s1 =6at t’

20. Dmw'thepréssure distribuaon(innon-dimensional foñn) along the

coatactlengthqfthe roll duriag
:rolling ofa s@. Show and’explain the salient cllaiacteristics pn tbis-curee.
Also
explaintheekectofbacktension aixt fronttenionwhcnappliedia&plaoeof&stnet-ped iaAe-
rollingdirectmn.
. .-ME64 Juiy-06:—
im.

1. What is drawing process: ’Explâin.

06ME73
’Oec 11—5 m
2. Drawthe-crins-sectionofa,;lmwing,dieand explaiathe differeatelementsofdrawk;g
die.
"
ME64
Juty05-M’zn
3, Dm the ‹aces sectiooalyiew ofcooicaldra gdic and explaia,ihe ng
ifican ofdif r
t
8. Starting fnmfuadamentah, deri*eaaesp;essioafor.drari4astreesbrstab.a°siysis.
. blE64 JaJyJi9- l0’m 9.. Deriveanespression for
drawieg,stresaincaseyfroddra;vingriab«»spai
ME64 fan10-.10m
10. ,Bywipgshb’anaijeu,.finâ,tbegxpwssionfor@ap piress
duringstrip‹ifawipgofi*¿ific-s&a. -
: «+s‹r«ro›-«
ll. Detenniéethe djaring force and d:awi;gpowerwms„0rawingaiyirétbniugbdio.

246
Manufacturing Process -IN

14. What is redundant work in drawing. How is it estimat&.

06ME73 Dec 11 —7 m
15. Explainoptimalconeapgleanddead zone fonnationindrawing. ME64 July
08 —4 m
16. Discussthedead zone formationindrawing opmtion.
ME64 Jan09 -6 m
17. Briefly explain optimd cone angle and dead zonefomationin drawing. 06ME73
Jaa10-4 m
18. What are drawing variable. Explain brie0y.
06ME73
July 11 —5 m
19. Explainlesteps kitubedrawing process.
06ME73 July
11 —5 m
20. Withaneat skdch explainmbedrawing prtxess.
06ME73 Dec 10—6m
21. Classifythedifferent pnx›esses m& intubedrawing. Withtbe help ofsuitable
sketch, nplai4 the
process using moving mandrel.
ME64
July 06 - 5 In
22. Explain the manufacture ofseamless tubes wi4 a neat sketch.
ME64 Jan 09- 8 m
23. What is dnwing. %1 a neat sketch describe the process ofcontinuous wire
drawigg.
ME64 Jaa 10-5 m

24. With a flow cfiart, show the steps involved in wire drawing.
Unft—6 Extruslon
06ME73 July 11 —4 m
1. Classifyandexp1aintheexnsioupws:ess.
ME64 Jan 07 —5 m
2. With neat sketcha explain brie0ydirect and indirectextrusion. ME64
July05—08 m
3. Withsuitableskdches explainindirect and hydraulic extrusin. ME64
July 06 -6m
4. Explain backwad extmsion process with a neat skdch. 06ME73
Dec10-6 m
5. Withneat sketchexplainimpact extrusion.
ME64 July 08
—6 m
6. Explaintheprincipleofiinpact extnision List its advantages & application.
ME64 Jan 10- 5 m
7. Givetbe classification ofextrusionpiocess and explain hydrostaticextrusionp
ss with a neat
sketch.
06ME73
Janl0—8 m
8. %thaneatsk£chnplainextrusiondie.
ME64July09— l0m
9. Wrieanoaonexnsionequipment, diedesigoand lubrication. &ME73 Decl0-6m
10. Show lenatureofmetal0ow patem in the extnision pnness with and witlxiut
lubricati
ME44May0-4m
11. Showhowmetal0owpattemvarieswi1andwithoutfrictioninextrusi‹xi,
witlisimplcsketc&e.
06ME73 Julyll —5 m
12. Brieflyexplainthedifferent defecmasociatedwithextiusion.
ME64Ju1y06—4m
13. Discuss any fourextmsiondefectswith their caases and remedies. 06ME73 Dec 11
—8 m
14. List any fowdefeca inextrusionandexplainanyone.
MH4July08—4m
15. Explain the folowing(a) defects in extrusion Q) lubriutionin ntrusion.
06ME73 Janl0— 12 m

247.

4. Claes@tbedilfereapiesstooh us& insheét.metal:fonning nidmakcacomparatimstudy

ofprses
kobonddfereet featurea. M£64
Julyfi-5-4m
S. ExplainanytwopuncbanddRSesigopatameterg,iadeepdrawipg. RE64 JulyN—4 at
6.’Listandexplain é
 briefleimportaaJdie and puachdesign parameters ofdeepdiasiAg..
. . MP64/ui 10— 5 .m
7.. How are dies classifi&. .Esplainw{iboeats£nctiastwoimporlant typesasapplied
&slget, metalwork

ME64 Julie 10-10 m

,8. Writcañote on die and punch materialia aheet-metalformiag.’ 06Mn73 Dm 11
- i m
:.9.. Disiaissthee&ect:of{ ovi p clearanceinshearing pt&ass:
10.’ Give,tbeclassifiutimofdi>insheetmeial fonniggandexplaié.combioat%dR«4jJttcat-
Adch.
06MB73
lfaO-7m
11. WiAt& help ofsuitablesRkh,exp1ainbriefiy’tliémode ofmetaldeAriz1at1aiaod‘$%o&.

ma -mio: e- e. -
an - m 13.’%thaneatsketchexplaiAapiogressivedie.-
-’
-MB64.Jn1yl0-8m
14. Withaneatsketchdcs»n”betheprocessofprfigressiveformigg. . ,ME64 Jan 10
— finn’ 15..
Withaneats1;etchexplahoombitiationdie. . -
MBd4iâitM-6‘zu.
!6.. withe»«tsketcfi,explain1eworkipg’ofprogressiveand-c+xnpmmddâanmg«s«aiastmt

248
f7: Vfahaen sk<cJiuggplainc0nibinati die and pr0gres4'vedie.
r»iu»ig›eorpmpoi»ia«'

produced insheetmetalwork. .’ . "

. . .
QME7j:Julyll- l0u-
-18. Draw neatsketches oscompound fiieandprogressire die. ,
Bne0yexpl’a.iatbe.rprn..ictplsof ’
Wp,jgpg. ’ ,
ME64
July05 —5+5,r }0 jn
19. What are the differenCe$b tw en o ipoundand 9rogresjiye dies,
ME64 Jap 09 ’6m
20. Mass qrodue«on ofmetal washws is to be made from steel sheet. Use suitgbl-
e'diefor-tlsi$

type ofpieduction ofdie used. ’

Hence, sxplaintheprocedure-ofoianufacturiag with necessary'ske &a
ME&,July06—?id:

21. Explas. ihow cm.

cular.’y‹ashemare prp: duâedgsin,
g,acompound ae. ME64 Jm. 0.— $»
22. Exp1ainbric@ytheyubberfonpiligproces• with respect to sheet metal fornimg.
ME64 July06—5,m
23. Explaiawithaneasketcbopaibackincliaable(QBI)p Sb. ME64
Jan:09-62R
.2.g.’„Descrifietbe’wo›kiggofan open backinclinabk (OJiS Press. What are
its'ndvantages.
. . ME64 Jaa-l0— 5&
Explai°c1eadywitb°eatsketches<, *>'.>'*%8 openiti'mpien:i°g, bla°kipg,-bera@'a,
fnrmiggandndlbending.. . .
ME64 Juael0r
l0pt
26. Discuss the ffiUowing processesi.a set ifiqtal forgoing: ,( ) nill
ixmdigg (b)
blaolfigg’;(‹t)

embossing(d) deep dnwi-ng

27: mth&elielpofsuitablesketchiifbendingpt «
06ME73 D II -”8 m
Definespring‘backand springback;atio ñbeoding, . ME64 July05 —"2+3+1 = 6
m-
S9.. gn.cQexplai.atbe,pn.n. cipleof%e›diaw-»ga°d 1utsfewdefect-s
mdeep,,j,g..•'°P,g,j•*°-

nAd4 June,l0’—8 m
31. .Sboq tbediffereotnomenclatureassociatedwitf:’i - •, Wh" a- t
is LDR. What
ISO" qSe;:t ofapinotropy on LDR. .
ME64 July
0S=3+2-i-2—7&
3’1,wba ii ikniti,igdn,wingnuo. .Exp1aiaanytws.defects iañee;i‹1;awii:i8P«*w’°•-.
ME&JYyps—6a*
?1.. ,Explaiñtbé’‹;ffect.ofañisotropyon LimitedDraw Ratio(LDR) iadeepdiawiog.

Powder Metallurgy
1. Explain brieflythe basic steps ofpowder metallurgy.
ME64 Jan 07—7 m
2. With a Oow chartexplain ie opemtion involved in making powder metallurgyparts.

3. Dmw the outline ofprocesses and opentions invoiv& in making powder

metallurgyparB

4. What are the different factors that influence ie powder metallurgy process.
Brie0y explain

5. List some ofthe important characteristics ofmetal powders. ME64

July09—6 n
6. What is powdermetalhirgy. Explainany2 methods ofmetal powder production.

7. Explainbriedya< various methods ofpowderproduction.

8. Explainanytwo methods ofpowderproducaor»
9. Give abriefdescriptionofmethods ofproduction of metal powders. ME64 Jan 09
— 8 m ;
10. Explainleatomization method ofpowder production in powdermetalluigy.

11. Explain briedylediReient characteristics ofmetal powders and their effect

onthe phpical
piq›ertiesofthecompacted products.
12. Withneat skekhes explain Briqueting operation.
13. Write anon oncompactionaixl wintering in powdermetallurgyprocess.ME64 Jan 09-
6 m
14. What is siniering. Explain its mechanism.
15. Explain briefly different sintering mechanism
16. What do you understand by‘presintering’ and 'wintering’. Explain. ME64
July06—5 m
17. What are the various finishing opemtioos carried out on powder metallurgy
product aAer
wintering. Explain anytwo ofthem.
18. What are &e various finis%g opemions carried out in powdermetallwgicalproducts
after

21. Explain HIP withaneatagu«.

22. Explainhotisostaticpressing'used forcompaxioiofmetdpowdem. Shew
howthetanpeiature and pressue
varia inside the pxss.
23. What are the advantages and limitaCons ofpowder metallurgy. ME64
JulyO5 —5m

A2

PNNS Seozeate B.E. Degree Ezszzdsatioa, Deceosber 20t2 ”

,

I a. m4 nmt skaclim, exp&in the classzficaooo A egal w‹rkigg pixggsm ‹xi @

§ealq
force applied
(10
b. Derive an expression for true stres and true strain
(05
“ ’’

2 a. Disease the effM of various paran twa‹al tr&al working pwcms.

(10 Maigg
b. Explsia defonnaaon»x›e gmizgry.
(05 M
c. Det inc engineering strain, true strnin aixl reduction, (i) Fa a bar
which é dnifil&ñ..
length u3 For a bar which is halved in loigt
.(0â
3 a. Drive an exprmsion for forging prmsure and load ia opai ñe f›xgieg by s&b
analygink
elidipg friction at tbcintaAce aad draw frictiwi hill.
(l0
Mar¥a}
b. A circular disc of lmd of radius 150 mm azgl tbicknms 50 mm is forgggl
figlfits oijgJi@
tbicknms by ops die fzrginy Uterine the aiaximam forging force if the ood0cimt A
friction bawmi
jo0 and the die is 0.25. The avnago yidd strms is 4 N. (05 Mp&J

i -a wia«‹i>isi»tca expiandia‹rmityp« ofr»iting a›ii ana»g«imiu. po

x;iaj
b. CalculateroXiogkndi£sted iszz›t rokat30V» 6o‹oa40 mm
tbicksIab“uaâ›g(PIXI»oa) ,
d1«a«rox. J1›eslab» 7s0sa‹=id»A»su•aiogy=o.3,tbepua«trxiaao»w«sa16
w’«atwa»c«oa2oo«r*«atttewita»ra/roiia/a›ui/»«›e/«aeis»/w,»&,a» T&a N= 1J¥I rpm
aot1-0.5 Ip &
nfltiog (10 Mo€s)

s a. w«ie a noie o» uti«›au‹:= orr«hndant w»ik a diawiig

‹or x»aj
b. Explain with a iimt s£etch, tube drawipg per:as.
(07 Mar£a).

6 . » nil &ntch, explain backward extrusion preens. Why pos

involved in hac
m&
b. &a• a •mta‹ache‹p«ia kwact mo»as mx<a>. ‹is a/a»y
c. List out defects io mtrusioa snd czplato say oae
(O
5¥ata)
7 a. Explain Aefolowing opaations with not skaclm: (i) Rubber fig(ii)Steet&Q
(io Mai¥s}

VTU Question Papers

253
b. With neat sketches, eKplain the following dies: (i) Progressive dies (ii)
Combination dies.
(10 Marks)
8 a. With a flow chart explain the operations involved in making powder
metallurge parts.
(08 Marks)

b. Explain with a neat figure unconfined explosive forming process.

c. Explain with a neat figure electromagnetic forming process.

Fifth Semester B.E. Degree Examination, June/July 2013

Manufacturing Process - III
(0d Marks)
(06 Marks)

10ME 55
ri>e: 3 hrs .
Max. Marks : 100
Note : Answer any FIVE full questions, sele•'ting at least TWO questions from •••
p*
PART - A

l a. Stow are metal forming processes classified? Explain with

sketches.
b. Explain Tresca and Von-Mises criteria.
c. Discuss the plane stress and plane strain concepts.
2 a. Explain the effects of following parameters in metal working processes:
(08 Marks)
(06 Marks)
(06 Marks)
(i) Temperature (ii) Strain rate (iii) Friction and lubrication
(10
Marks)
b. Comment on : (i) Deformation zone geometry, (ii) Residual stresses in wrought
products
(10 Marks)
3 a. Derive an expression for forging pressure and load acting in
plane strain
considering Coulomb's friction at the interface.
(08 Marks)
b. List and explain die design par tmeters in forging.
(06 Marks)
c. Briefly eKplain forging defects and residual stresses in forging.
(06
Marks)
4 a. Sketch and explain different types of rolling mills.
(06 Marks)
b. Discuss maximum possible reduction in rolling process.
(04
Marks)
c. A steel sheet is hot rolled 30% from a 40 mm thick slab using 900 mm diameter
roll. The slab
is 760 mm wide. The plane flow stress is 140 MPa at entrance and 200 MPo at the
exit from the roll
gap due to the increasing velocity. Assume p= 0.30. Calculate: (i) Rolling load
(ii) Rolling load with sticking friction.
(10 Marks)
PART - B

5 a. Derive an expression for drawing load by slab analysis.

b. Explain optimal cone angle and dead zone formation in drawing.
c. Sketch and explain tube drawing process.
(08 Marks)
(06 Marks)
(06 Marks)

6 a. Write a note on extrusion equipment, die design and lubrication.

b. Sketch and explain extrusion of seamless tubes.
c. Discuss extrusion variables.
7 a. Explain with figures working of progressive and compouriddie
Jrrangeinents in sheet metal
workings
b. With sketches; explain the operations: (i) Rubber forming (iiJ’Deep drawing.
a. With a neat figure, explain the following forming methods: (i)
Explosive forming
(ii) Electromagnetic forming.
b. Discuss with flow chart powder metallurge procms.
Time : 3 hrs
Fifth Semester B.E. Degree Examination, Dec. 2013/Jan. 2014 Manufacturing
Process - III
Note : Answer any FILE full questions, selec'ting at fears TWO question's from each
part.
PART - A
a. How the metal working processes are classified? Explain.
b. Define re-crystallization. Distinguish hot working from cold working.
(06 Marks)

Explain the following parameters which affects themetnl working processes: (i)
Temperature
(b) Strain rate effeéts (c) Hydrostatic pressure (d).Deformation zone geometry.

a. Explain with sketch the procedural steps involved in forging operation.

(06
Marks)
b. A solid cylindrical slug made of stainless steel is 150 mm diameter and 100
mm height. It is
reduced in height by 50% at room temperature by open die forging with flat dies.
Assume p as
0.2 and flow stress as 1000 MPa, calculate forging force at the end of the
stroke.
C. Derive an expression for slab analysis to deterrpine the mmn pressure for
closed die
forging.
4 a. Explain with sketch any three types of rolling mills.
b. Derive an expression to determine the roll force and power required in
rolling operation.

C. Determine the maximum possible reduction for cold rolling a 300 mm slab when p
is 0.08 rolling
when p is 0.5 ?

PAHT-B

c. p,xplaio with’sketch any two mabods

of4ubeaawiag, : .ttdHai£s)
6 a. Explain with Fch the direct Extrusion a&Ip

c. Explain in dekfil tl defonoatio$ lttt›8*=888'W '

"“’' '""" ),
) .
7 ’g, Explain with sketch the Jirogrmsive die and combination die in
p

(ii) Stretch formipg(iii) Ruby press fooling., .

.
)
c Meatier defeats in shnet aietal loaned
I& Hai •)
’8 a. Explaiawithskifchthefotlo%g1;ig6«i«grreteiiânik. g•>>•*• :

b. Explain diflieéiu st@s in pi›wdér izétallurgy pieéms.

: :''*.
Finh .Semester B.E. @e$zei Exuiglmtt'm, Juse/JelP t014

1 a. compare Hot working and Cmd -

.
b. Copper wir• has a nominal breakiagstnx;gih of 300 3fPn. or area, Cdculatc
the true stres for
fracture.

c. Derive the equation for princi

,': . .
2 a. Disiaiss the effmt of(i) Fnction ) Lubrication or metal worlfin3
prooma.
b. Writpa note on : (i) Deformationzo0e ge°°i&w(ii)>*°'J^@âY.'<%@QfQ,

3 a.
Classify and explain the various fmgip8 proc s, n t -

fiat dix to 25 mm heighL

The yield strength ofthe material iy givea as a = 100.0 (0.0085 + e)'3’ N/mm’ and
q -- 0.1

a: Explain the commonly used rolling mill arrangements in today's manufacturing

industry.

b. A roll mill has rolldia of850 mv. Calculate the maxitnumreduction

possibleiathis millifthe
coefficient of friction is 0.3. Determine the rolling load requir‹xl to obtain 25%
reductionef a
metal strip of 35 mm thiclmess using the same rolling mill, given the average yield
strength ofthe
mtal as 180 MPa and strip width as 690 mm.
PART - B
a. Discuss redundant work and its estimation in drawing.
b. List and explain a few important process variables that affect the
drawing force in
wire
drawing process.

«.

b.
c.
7 a.
b.

a.
b.
C.
Explain tube drawing with a floating maodrel.
Explain the sketches : (i) Indirat extrusion (ii) Hydro static extrusion Write a
note on extmsion
dix.
It is required to extrude an Aluminium alloy at 380°C tixough square dies from 140
on to

is 240 MPa. Determine the extrusion force with the following data. Length ofthe
bill is 450 mci,
Semi-die angle is 450 ; Coefficimt of friction between work surface is 0.15.

Explain the types of multi operation dix, witd not sketch

Calmlate the maximum punch force and the work dooé required to blaok a
44.45 mm outsidedia and 22.3 nni insidedia fmma 1.59 mv thiCk rectangular sheet
witii8fl ultimate
shear stress of 432 N/mu' and Ae % pmetration is 2tPZe. (08 Merks)
Discuss any 3
methods of production of powders
List the advantages and disadvantages of HERF.
Explain: (i) Elmtromagnetic forming (ii) Hot Isostatic Pressing.

FtRb Sezztester B.E. Degree Exaoñostioa, Dec.20t4/han.2015

Time : 3 hrs

a. Briefly explaia'the classification of forming process based on force applied.

b. Explain the following yield criterion (i).Tresca's (ii) Von-Miss

c. Derive the flow stres equati‹xr

f05 Marks)
2 a. Discun tbs eftigt ofvario«s paraiz«ara on eiaal aoñfin$ '
(10
Mar£s)
b. DiR«ice bawmi cold working aial hot xc&io$ pimms. (05
Harks)
c. Write a note on workability of iaSerials,
( IS Mark)
3 a. What pe tbg asmmptioas ma& &ñle analyzing forces during forging?
Dnivc the
exprmsions f‹r fori;ing prmsurm aod lmd in opm die forging by aBb analysis
(alidig$
eccurs at intwfaoe). Hence find mean forging presurn (i) With
at”@
interface. (ii) With ‹xinstimt friction factm at the
(lil
Me$s)
b. Witb ntat 3ketcQ explain the w of"Bond-dmp ln4ti0m".,
O4 bdnrksJ
c. Explain the paramefrs to be oomidned‹£irkig 4ie i8
(D4
£Krka}
4 - n R *
- I I
b. Explain AcdeCossofOMedpnxfuA
’(OJ M«itsl
c. In rolling a slab from 35 to 30 calculate the coefficimt of fxictioo azid
the l
arc of contact. Take the value of roll radius as 250

5 a. What is drawing proceed? Explain

b. What arc the drawigg variable† Expr briefly.
c.
apy one process. '
A Explain optimal cmeaggle aild dgd zozm feiznation ia draxigg,
6 a. Gvc the claasifical$m ofeetrnGim pn›cms aod 4xplaizi hydnn&tic m&esRt@@
a@t

c. It is required toextradeacylin&ical aloaiitena £M

& t0
. The length ofthe billet is 75 mm aixl the a
tata l is 17a N/ . Calculate the
ibrwde
ion! p >0.IS owl ski-die

7 › a. Witb neat sketcb, exptaJa . , of ‘ve‘

eod’co‹apoazd & "
ia
*m*<*•‹ +***%s- ›- » ",
f*****Ot
b. Explainlhe forming limit
c. A 25 mm aquare hole ig
the matwial is 2.86 lW
8 a. Disclis$ Aa principle of wo
(ii) Ei«zro hy&aulic forming.

Time: 3 hrs
Max..Marks: IO

a. w:a axt skacbe, aplain & classifiwtioa ofa›aaI worlciag pr•,=•s•• m tbs
beais of
force applied
 (10 Mail)

2' a. Ezplsé iRamml #m y‹bosMâcpsssmsio ww#ipg, (05Ma6 )

I &• PSI DC
.
b. Write a ix›te on material flow line in
c. ml a timt skack explain aay Lo Forgigg «juipawia.
4 >- Cth not oimfchea, explain the dike type ofrollipg mills.
(0fi Marka)

c. A 300 rim widcaluminiuni alloy strip is ti°: D¥o1from na initial tbickzms of 25

to a
final thic&ws of 15 mm The diaizi&u of& rolh a ’1 nlaDd ofmta is
120 rpm
70 MPa at the mtranceofrolls and 110 MPa at the exit âte
the ro9 gap aie io i»crmsigg wlecity. r»n
p- 0.25 and k= 0.5.

* a. What u drawing† mth a‘amt ak«ch uplaia tlg prtgms of rod drawi„g.-
(pg j;jg,pg)
drawipg ma the help of aiiablu akg«i

explain Ac pimma ofng›ving mggdrel.

c. Eéplain optimal oone aggle tttgJ
6 a. Withanutstmtch,explaia

b. BñefympbinécmeelSow
v. List and explain the various
7 a. m&nmtsketchu, explafiiAe
a at' maal werki''g *
b. With not skachm expiaia the fo
(ggg„;g)
. (MMeAQ
(07 Marba)

(l0 Marka}

b. With a flow chart explain the op«ationa involved ia making powdg mgalj;;igy
partg,
c. List the applicaéota off metallurg‹ .
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