Homework 3: Metalworking Processes (due Wednesday February 3rd))

1. (a) Impression die forging is commonly considered to be capable of making 3D shapes. State
one major constraint for this method in terms of its 3D shaping capability.
(b) A cylinder of metal that is originally 100mm tall and 70 mm in diameter must be open die
forged to a height if 50mm. The strength coefficient is 400 MPa and the work hardening
exponent is 0.2 while the coefficient of friction of the metal against the dies wall is 0.1.
Determine if this forging operation can be accomplished using a forging hammer with a capacity
of 1,600 kN.

2. (a) How does contact length affect roll force?

(b) Estimate the roll force when a strip of metal 0.5 m wide is reduced from a thickness of 50
mm to 45 mm in one pass, without lateral spreading. The strength coefficient is 300 MPa, the
strain hardening exponent of 0.15 and the roll contact length is 40 mm. Assume no friction.

3. A cylinder of diameter 200 mm and height 400 mm is subjected to open-die forging to

accomplish a reduction in the height to 200 mm at high temperature. Calculate the magnitude of
the force required to give this reduction in height if the strain rate is constant at 50 s-1. Assume
the strength constant is 120 MPa and the strain rate sensitivity exponent is 0.1. Also assume that
there is no effect of friction with the tooling and no work hardening.

4. (a) How are centerburst defects formed in extrusion?

(b). Determine the extrusion pressure for a 150 mm diameter cylinder of metal extruded to a final
diameter of 75 mm when the strength coefficient is 250 MPa and the strain hardening coefficient
of 0.2. Assume that there is no friction.