Faculty of Engineering – Cairo University

Mechanical Design and Production

Engineering Two Semesters System – 4th Year

MDP 412 – Computer Aided Metal Forming

Assignment (3)
Ring Test Verification

Submitted To
Prof. Abdalla Wifi

Eng. Mohamed H El-Moayed

Prepared by Group (1)

Name B.N
Anton Tamer Shafique Abdel-Sayed 12
Ayman Hisham Mahmoud Ahmed 13
Sarah Hussam Marzok El-Ganzory 15
Mohamed Ahmed Morsi Ahmed 23
Mohamed Ashraf Mohamed Osman 24
Mahmoud Ahmed El-Sayed Kassab 28
Hager Ali Mahmoud Ali 35

April 26, 2021

 1. Specimens’ materials:
o Aluminum.
o Steel.
o Ms70/30 brass.

2. ABAQUS finite element code results:

3. Coefficient of friction correction:

Here, initial and final dimensions are used to get the apparent coefficient of friction.

3.1. Governing equations

Conditions:
O.D O.D
. I.D. = 2 & Ht
=3

Equations:
𝐼.𝐷.𝑖−𝐼.𝐷.𝑓 𝜇
o 𝐶ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟(∆𝐷%): 𝐼.𝐷.𝑖
𝑥 100 = 𝐾 𝑥 ln (0.055)
o 𝑙𝑛(𝐾) = 0.044 𝑥 %𝑅𝑒𝑑. 𝑖𝑛 𝐻𝑡. +1.06
𝐻𝑡𝑖−𝐻𝑡𝑓
o %𝑅𝑒𝑑. 𝑖𝑛 𝐻𝑡. = 𝐻𝑡𝑖
𝑥 100

Initial dimensions:

o 𝑂. 𝐷. 𝑖 = 60𝑚𝑚
o 𝐼. 𝐷. 𝑖 = 30𝑚𝑚
o 𝐻𝑡. 𝑖 = 20𝑚𝑚

O.D 60 O.D 60
. I.D. = 30 = 2 & Ht
= 20 = 3 Conditions are valid
o %𝑅𝑒𝑑. 𝑖𝑛. 𝐻𝑡 = 40%
 3.2. Aluminum ring calculations
Final dimensions:

o 𝐼. 𝐷. 𝑓 = 23.3𝑚𝑚
o 𝑂. 𝐷. 𝑓 = 72.24𝑚𝑚
o %𝑅𝑒𝑑. 𝑖𝑛. 𝐻𝑡 = 40%

.𝑙𝑛(𝐾) = 0.044 𝑥 40 + 1.06 = 𝟐. 𝟖𝟐 → 𝐾 = 𝟏𝟔. 𝟕𝟕𝟕

30−23.3
.𝐶ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟(∆𝐷%): 30
𝑥 100 = 𝟐𝟐. 𝟑𝟑%

𝜇 𝜇
.𝐶ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟(∆𝐷%) = 22.33 = 𝐾 𝑥 ln ( ) = 16.777𝑥 ln ( )
0.055 0.055

𝟎.𝟐𝟎𝟖−𝟎.𝟐
.𝝁(𝒄𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅) = 𝟎. 𝟐𝟎𝟖 > 𝟎. 𝟐 𝑬𝒓𝒓𝒐𝒓 % = 𝒙 𝟏𝟎𝟎 = 𝟒%
𝟎.𝟐

3.3. Steel ring calculations

Final dimensions:

o 𝐼. 𝐷. 𝑓 = 24𝑚𝑚
o 𝑂. 𝐷. 𝑓 = 72.24𝑚𝑚
o %𝑅𝑒𝑑. 𝑖𝑛. 𝐻𝑡 = 40%

.𝑙𝑛(𝐾) = 0.044 𝑥 40 + 1.06 = 𝟐. 𝟖𝟐 → 𝐾 = 𝟏𝟔. 𝟕𝟕𝟕

30−24
.𝐶ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟(∆𝐷%): 𝑥 100 = 𝟐𝟎%
30

𝜇 𝜇
.𝐶ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟(∆𝐷%) = 20 = 𝐾 𝑥 ln (0.055) = 16.777 𝑥 ln (0.055)

𝟎.𝟐−𝟎.𝟏𝟖𝟏𝟏
.𝝁(𝒄𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅) = 𝟎. 𝟏𝟖𝟏𝟏 < 𝟎. 𝟐 𝑬𝒓𝒓𝒐𝒓 % = 𝟎.𝟐
𝒙 𝟏𝟎𝟎 = 𝟗. 𝟒%
 3.4. Ms70/30 Brass ring calculations
Final dimensions:

o 𝐼. 𝐷. 𝑓 = 25.18𝑚𝑚
o 𝑂. 𝐷. 𝑓 = 72.5𝑚𝑚
o %𝑅𝑒𝑑. 𝑖𝑛. 𝐻𝑡 = 40%

.𝑙𝑛(𝐾) = 0.044 𝑥 40 + 1.06 = 𝟐. 𝟖𝟐 → 𝐾 = 𝟏𝟔. 𝟕𝟕𝟕

30−25.18
.𝐶ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟(∆𝐷%): 30
𝑥 100 = 𝟏𝟔. 𝟎𝟕%

𝜇 𝜇
.𝐶ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟(∆𝐷%) = 16.07 = 𝐾 𝑥 ln (0.055) = 16.777 𝑥 ln (0.055)

𝟎.𝟐−𝟎.𝟏𝟒𝟑
.𝝁(𝒄𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅) = 𝟎. 𝟏𝟒𝟑 < 𝟎. 𝟐 𝑬𝒓𝒓𝒐𝒓 % = 𝟎.𝟐
𝒙 𝟏𝟎𝟎 = 𝟐𝟖. 𝟑𝟑%

4. Discussion:
There is a difference between ABAQUS coefficient of friction and that obtained from equations
because:

o Experimental results represent the real behavior of the ring under test with specific
measuring errors.
o Simulation results represent the behavior of the same ring based on its theoretical model.