Manufacturing Processes Tutorial 1 Solution

a) Brass tubing, labelled A. Extrude (hot) and then cold draw by tensile drawing to
reduce diameter. Tensile drawing must be done cold. If done hot, the material will
be too weak and will break into two during pulling. Then cut to length. Drawing
gives straightness. Dimensional accuracy is a plus point but is not really necessary
here since the chimes do not play real notes.

b) Drum barrel, labelled B. Cold roll sheet down to thickness of 0.5 mm. Then shear
off to size and wrap round. Seam can be joined mechanically (staple or screw) or
by gas welding or spot welding. Rivetting is an overkill. Too thin for TIG or any
arc welding process. Stainless steel needs shielding from atmosphere when it is
welded to prevent the chromium from oxidising. Can be gas welded but must be
done with flux (protects weld from air).

c) Drum stands, labelled C. Most common method employed locally is by using

rollers to form the 2 mm strips into tubes and weld the seam by electrical
resistance or inductance (Eddy currents). Fast economical method for large-scale
production of tubes. In this case, a seamless tube is not required. However, for
critical high-performance cases (aircraft parts, rifle barrels and elevators), it is
important to have seamless tubes and pipes, produced by the Mannesman (central
piercing) process or the extrusion process. Rifle barrels need to be extruded and
then the central bore drilled through for accuracy.

d) Legs of the stands, labelled D. Cold rolling to get nice smooth shining surface.
Large hot ingot is rolled to plate. Then plate is pickled and cleaned with acid and
acetone until shining (oxide layer eliminated). Then it is cold rolled to size. Since
it is mild steel, it is necessary to chrome it for corrrosion protection.

Cymbal

(i) Blanked part is larger than the die by the allowance (50 microns)

Die diameter = 400 mm - 0.05 mm = 399.95 mm

Punch diameter = 399.95 - 2 x (Clearance of 0.1) = 399.75 mm

(ii) Pierced hole is smaller than the punch by the allowance (50 microns)

Punch diameter = 10 mm + 0.05 mm = 10.05 mm

Die diameter = 10.05 + 2 x (Clearance of 0.1) = 10.25 mm