IIT Guwahati

ME 513 Physics of Manufacturing Processes

End Semester Exam / May 2020
Total: 70 marks
Duration: 36 hours
Start time: 10 am; May 15, 2020

Answer all the FIVE questions. Data not given can be assumed suitably.

[1] A circular cylinder of 100 mm diameter and 160 mm height is compressed to 40 mm

height between two flat dies at 1000°C. Considering sticking friction over the entire
contact area of the disc, determine the maximum die pressure and average die
pressure. The yield strength of the material is 75 N/mm2. (10)

[2] (i) Explain the state of stress in the flange region during cup deep drawing and indicate
the points in the yield locus.
(ii) The plane-strain flow stress of a metal plate is 250 MPa. The plate is 0.6 m wide
and 3 mm thick. This is rolled to 2.5 mm in a single pass using 30 cm diameter rolls.
Assume coefficient of friction as 0.1, find (a) the average roll pressure without front and
back tensions, (b) If front tension of 66 MPa is applied, how will you calculate the
average roll pressure? (5+10 = 15)

[3] Consider the modes of deformation A, B, C shown in the Figure 1 at which a metallic
structure is plastically deformed. Find the effective strain for each mode using the
following yield functions.
(a) von Mises yield function
(b) Hill non-quadratic function (𝜀̅ given below) with r = 1.75 and M = 2.5.
M 1
1
 M 
M
[2(1  r )]
M
 M 1 
M
1
   1
( 1   2 ) M 1
 ( 1   2 )

(10)
2
 (1  r) M-1 

Figure 1
[4] A homogeneous deformation is imposed in the plane of a sheet. Two lines painted on
the surface move with coordinates measured as shown in Figure 2. (a) Find ‘F’, (b)
Using F, find C, E and ε, and (c) Find the principal strains of E. (10)

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 x2 x2
BEFORE AFTER

(3.1, 3.3)
(1.8, 2.1)

(2, 1.5) (3, 2)

(1, 1) (4.1, 1.9)

x1 x1
Figure 2

[5] Answer the following. (5×5 = 25)

(i) Explain how will you evaluate strain rate sensitivity (m), and its relation with necking.
(ii) State upper bound theorem with nomenclature clearly explained.
(iii) Explain processing maps in hot working with its significance. Also, explain the
significance of G-content and J Co-content using a constitutive relation.
(iv) What is autofrettage of thick walled cylinders? Explain how this helps in improving the
fatigue life of cylinders.
(v) State Levy-Mises flow rule and Prandtl-Reuss flow rule, and explain the difference.

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