1.

In rolling, spreading in flat rolling increases with (a) decreasing width to thickness ratio
of the entering material, (b) decreasing friction and (c) decreasing ratio of the roll radius
to the strip thickness. Explain why for each of the above.

Answer:
In the rolling of plates and sheet having high width-to-thickness ratio, the width of material
remains effectively constant during rolling. With smaller ratios, however, such as with a square
cross-section, the width increase considerably in the roll gap, as a result of the same effect that
occurs in the rolling of dough with a rolling pin. This increase in width is called spreading.
The roll force in the flat rolling can be estimated from the formula F=LWYavg, where L is the
roll-strip contact length, W is the width of the strip, and Y is the average true stress of the strip in
the roll gap. This equation ideally, is for frictionless situation. The higher coefficient of friction
is between the rolls and the strip, the greater becomes the divergence, and the formula predicts a
lower roll force than the actual force.

a) From above, it can be shown that spreading increases with a decrease in the width-to-
thickness ratio of the entering material, because of reduction in the width constrain.
According to the formula F=LWYavg when the width increases by a particular ratio the
force increase proportionally. Also we can calculate the value of L in above formula from
L=√ R(h 0−hf ), and it can shows that the value of initial thickness h0 increase by the same
particular ratio as width, the value of L does not increase according to the ratio since it is
under square root.

b) The friction at the interface between the material and the rolls causes the material to be
pushed through. The amount of deformation possible in a single pass is limited by the
friction between the rolls; if the change in thickness is too great the rolls just slip over the
material and do not draw it in. Then with increasing the friction, value of the normal force
from the rolls to the strip will increase and that cause, more spreading as outlet.

c) According to F=LWYavg and L=√ R(h 0−hf ), we can see that by decreasing ratio of the
roll radius to the strip thickness will result to greater force F. Because if the value of the R
and h0 decrease by the same ratio, then the value of L and finally the amount of force F
will increase.
2. What is the minimum bend radius for a 0.9-mm thick sheet metal with a tensile
reduction of area of 25%? Does the bend angle affect your answer? Explain.

Answer:
The following formula is used to calculate the bend radius:

According to the formula above the radius is not depended on the angle, therefore it does not
affect my answer.

R= 0.9(50/25 – 1)=0.9(2-1)

R=0.9

3. What is the bend allowance of the same sheet metal if the value of k = 0.33 and  = 600?

Answer:
The bend allowance is calculated from the formula below:

α = 60 and K=0.33

Lb = 60(0.9+(0.9*0.33))

Lb= 71.82

4. What are the advantages and disadvantages of rolling at :

a) Very high speed; and

b) Very low speed.

Answer:
Very high speed:

The advantage is having higher quantity of production than rolling at very low speed in same
time consumed. It means higher speed will result to produce more parts. This will require less
labor cost, power consumption and maintenance, therefore rolling at very high speed decrease
the costs.

The disadvantage is having less control during the rolling process due to the high speed of rolls.
If any defect appears, it is kind of difficult to realize and find it. These disadvantages will result
to have not good surface finishing.

Very low speed:

The advantage is having more control during the rolling due to the low speed of rolls. Another
advantage is if there any defect it can be observed and found easily. These advantages will result
to have better surface finishing.

The disadvantage is having less production quantity with the same amount of time in compare
with rolling at very high speed. On the other hand, as the time consumed increases labor cost,
power consumption and maintenance will increase accordingly, therefore rolling at very low
speed costs more than rolling at very high speed.

5. How can you tell if a part is forged or cast? Explain the features that you will be looking for.

Answer:
Forgings are consistent from piece to piece, without any of the porosity, voids, inclusions and
other defects. Thus, finishing operations such as machining do not expose voids, because there
aren't any. Also coating operations such as plating or painting are straightforward due to a good
surface, which needs very little preparation.
Casting is a manufacturing process by which a liquid material is usually poured into a mold,
which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified
part is also known as a casting, which is ejected or broken out of the mold to complete the
process. Casting materials are usually metals or various cold setting materials that cure after
mixing two or more components together.
Forging output would be not very complex and smooth, easy to finish by painting or polishing,
without much extra efforts. However, casting is used for complex end products, with the output
needing a lot of scraping, smoothing before finishing.

6. Using a diagram explain the differences of open die forging and closed die forging.

Answer:
open die forging uses simply-shaped, non-encompassing dies to hammer or press a metal
workpiece into a certain shape. It is distinct from closed-die forging, in which the dies fully
enclose the workpiece when they are brought together. The open die forging process allows for
larger products to be forged than other types of forging- up to 150 tons and 80 feet long or more.
Open die forging is used most often to produce round, square, rectangular, and hexagonal bars,
beams and other basic shapes. Other common products formed using open die forging include
spindles, hubs, mandrels, step shafts, metal shells, simple pancake forgings and pierced blanks.
Since tooling tends to be simpler and lower in cost for open die forges than for closed die forges,
open die forging is better suited for lower volume production runs and for creating unique forged
items. The pressure applied during the forging process gives metal improved grain structure,
higher density, decreased porosity and therefore additional strength and longer service life as
compared to cast metal products. Open die forging works well with any metal, including carbon
steel, stainless steel, copper, nickel, aluminum and titanium. Industries that benefit from open die
forgings include aerospace, automotive, material handling, marine, military, cement, electronics
and home appliances.

Open-forging is where the solid work place between flat can reduce the height by compressing it.

Flashes remain in open die forging. Very accurate blanks are not required and needed

Closed die forging, also known as impression die forging, involves the pressing or hammering of
preformed metal blanks into a set of dies shaped as a three dimensional negative of the part to be
produced. In closed die forging the hammer and anvil fully enclose the workpiece, forcing the
metal to fill all areas of the die. Closed die forging can produce a nearly limitless variety of 3-D
shapes, and is capable of producing complex parts with tight tolerances. Closed die forging is
distinct from open die forging, in which the die only comes into contact with part of the
workpiece at a time. Initial costs for developing the processes and tooling for closed die forging
can be quite high, but it is the most cost-effective forging method for high volume production,
since recurring costs for each part are very low. In addition, closed die forging is capable of
producing both symmetrical and non-symmetrical parts. Materials that frequently undergo closed
die forging processes include high alloy steel, naval brass, carbon steel, aluminum, alloy metals,
stainless steel, copper, nickel, tool steel and titanium. Closed die forgings are used particularly
often by industries such as electronics, aerospace, automotive, commercial, manufacturing,
semiconductor, construction, hardware and food processing.
Closed-forging is where the flash does not form and the solid work completely fills the die
cavity. It is done by upper die and lower die.

In closed-die forging no flashes remain. The material will fill at the die cavity. It requires having
very accurate blank size.

7. What would be the major design considerations taken into account to curb the common
bending defects on sheet metals. Explain with neat sketches and diagram.

Answer:
Bending is a process by which metal can be deformed by plastically deforming the material and
changing its shape. The material is stressed beyond the yield strength but below the ultimate
tensile strength. The surface area of the material does not change much. Bending usually refers
to deformation about one axis.
Precision sheet metal bending is not always easy operation. Poor bending tool design and
manufacturing can result in the following bending defects:
1. Insufficient angle on bend part due to spring back 
2. Scratch mark on part
3. Thinning of sheet metal at bending area

In order to curb and avoid these common bending defects, we must take the following tips
mentioned below into account:

a) Choose the correct bending operation.

b) Using large radius would reduce stress concentration.
c) Verify the clearance between bending punch and die.
d) Bending sharp radius can be accomplished through scoring or embossing
e) Provide adequate bending radius and polish it to high surface finish. Bending radius is the
radius on the bending die on which the sheet material flows to form the desired profile.
Hence it is important to have very good surface finish at this area for smooth flowing of
material.

8. Explain the difference between punching and blanking.

Answer:
A blanking die produces a flat piece of material by cutting the desired shape in one operation.
The finish part is referred to as a blank. Generally a blanking die may only cut the outside
contour of a part, often used for parts with no internal features.
Punching is a metal forming process that uses a punch press to force a tool, called a punch,
through the workpiece to create a hole via shearing. The punch often passes through the work
into a die. A scrap slug from the hole is deposited into the die in the process. Depending on the
material being punched this slug may be recycled and reused or discarded.
Thereupon, in punching the slug is discarded (scrap), while in blanking the slug is the product.