MANUFACTURING II

BULK DEFORMATION PROCESS

Tutor:
Ing. Luca Giorleo
Rolling
 Exercise 1

A 42.0 mm thick plate made of low carbon steel is to be reduced to 34.0

mm in one pass in a rolling operation. As the thickness is reduced, the
plate widens by 4%. The yield strength of the steel plate is 174 MPa and
the tensile strength is 290 MPa. The entrance speed of the plate is 15.0
m/min. The roll radius is 325 mm and the rotational speed is 8.0 rev/min.
Determine:

(a) the minimum required coefficient of friction that would make this
rolling operation possible,
(b) exit velocity of the plate, and
(c) forward slip.
 Exercise 1 - Solution

(a) the minimum required coefficient of friction

d = t o−t f = 42 − 34 = 8m m

d max = μ 2 R ⇒ μ = d R = 0.157
 Exercise 1 - Solution

(b) exit velocity of the plate

w f − w0
s= = 4% ⇒ w f − w0 = 0.04w0 ⇒ w f = 1.04w0
w0
because material mass flow must be the same

t 0 w0 v 0 = t f w f v f

t 0 w0 t 0 w0 42 w0
vf = v0 = v0 = 15 = 17.8 m / min
t f wf t f 1.04 w0 34 ⋅ 1.04 w0
Exercise 1 - Solution

(c) forward slip

v f − vr
s=
vr

vr = 2π RN = 16.33m / min

v f − vr
s= = 0.09
vr
 Exercise 2

A 2.0 mm thick slab is 10.0 mm wide and 1.5 m long. Thickness is to be

reduced in three steps in a hot rolling operation. Each step will
reduce the slab to 25% of its previous thickness. It is expected that
for this metal and reduction, the slab will widen by 3% in each step.
If the entry speed of the slab in the first step is 40 mm/min, and roll
speed is the same for the three steps, determine:

(a) final length and

(b) exit velocity of the slab after the final reduction.
 Exercise 2 - Solution

(a) final length

d t0 − t1
r = = 25% ⇒ = 0.25 ⇒ t1 = 0.75t0 = 1.5mm
t0 t0
t 2 = 0.75t1 = 1.125mm
t3 = 0.75t 2 = 0.84mm

w1 − w0
s= = 3% ⇒ w1 = 1.03w0 = 10.3mm
w0
w2 = 1.03w1 = 10.6mm
w3 = 1.03w2 = 10.9mm
 Exercise 2 - Solution

because material volume must be the same

L0 w0t0
L0 w0t0 = L1w1t1 ⇒ L1 = = 1942mm
w1t1
L1w1t1
L2 = = 2513mm
w2t2
L2 w2t2
L3 = = 3254mm ⇒ L3 = 3.2m
w3t3
 Exercise 2 - Solution

because material mass flow must be the same

v0 w0t0
v0 w0t0 = v1w1t1 ⇒ v1 = = 51.8 mm min
w1t1
v1w1t1
v2 = = 67 mm min
w2t2
v2 w2t2
v3 = = 86.8 mm min
w3t3
Exercise 3

A series of cold rolling operations are to be used to reduce the

thickness of a plate from 50 mm down to 25 mm in a reversing two-
high mill. Roll diameter = 700 mm and coefficient of friction between
rolls and work = 0.15. The specification is that the draft is to be equal
on each pass. Determine

(a) minimum number of passes required, and

(b) draft for each pass?
 Exercise 3 - Solution

(a) minimum number of passes required, and

D
d max = μ 2 R = μ 2 = 7.875mm
2

d final t0 − t f
d final = xd max ⇒ x = = = 3.17 ⇒ 4 passes
d max d max

(b) draft for each pass?

d final t0 − t f
d pass = = = 6.25mm
x x
 Exercise 4

A plat that is 250 mm wide and 25 mm thick is to be reduced in a single

pass in a two-high rolling mill to a thickness of 20 mm. The roll has a
radius = 500 mm, and its speed = 30 m/min. The work material has
a strength coefficient = 240 MPa and a strain hardening exponent =
0.2. Determine

(a) roll force,

(b) roll torque, and
(c) power required to accomplish this operation.
 Exercise 4 - Solution

(a) roll force,

F = Yf wL
n
Kε n K ⎛ to ⎞ N
Yf = = ⎜⎜ ln ⎟⎟ = 148Mpa = 148
n +1 n +1 ⎝ t f ⎠ mm2
w = 250mm
L = R ( t0 − t f ) = 50mm

F = Yf wL = 1,852,068N = 1852kN
 Exercise 4 - Solution

(b) roll torque

L
T = F ⋅ = 46, 301, 695 Nmm = 46, 302 Nm
2
(c) power required to accomplish this operation

P = ω ⋅T
vr 30 1 1
ω= = = 60 =1
R 0.5 min s
P = ω ⋅ T = 46,302 Nm / s = 46,302W = 46kW
Forming
 Exercise 5

A cylindrical part is warm upset forged in an open die. The initial

diameter is 45 mm and the initial height is 40 mm. The height after
forging is 25 mm. The coefficient of friction at the die-work interface
is 0.20. The work material has a flow curve defined by a strength
coefficient of 600 MPa and a strain hardening exponent of 0.12.
Determine the force in the operation

(a) just as the yield point is reached (yield at strain = 0.002),

(b) at a height of 35 mm, and

(c) at a height of 25 mm.

 Exercise 5 - Solution

(a) just as the yield point is reached (yield at strain = 0.002)

F = K f Yf A

π
V= D02 h0 = 63,585mm3
4

⎛ h0 ⎞ h0 ε eε
ε = ln⎜ ⎟ ⇒ = e ⇒ h0 = = 39.92mm
⎝h⎠ h h

V
A= = 1593mm 2
h
 Exercise 5 - Solution

π 4A
A= D = 1593mm ⇒ D =
2 2
= 45.04mm
4 π
0.4 μD
K f = 1+ = 1.09
h

Y f = Kε = 284.6 Mpa
n

F = K f Y f A = 494,279 N = 494kN
 Exercise 5 - Solution

(b) at a height of 35 mm

V 4A
A = = 1818mm 2 D= = 48.12mm
h π

0.4 μD ⎛h⎞
K f = 1+ = 1.12 ε = ln⎜⎜ ⎟⎟ = 0.13mm
h ⎝ h0 ⎠

Y f = Kε n = 471Mpa

F = K f Y f A = 950,200 N = 950kN
 Exercise 5 - Solution

(c) at a height of 25 mm
V 4A
A = = 2543mm 2 D= = 56.91mm
h π

0.4 μD ⎛h⎞
K f = 1+ = 1.18 ε = ln⎜⎜ ⎟⎟ = 0.47 mm
h ⎝ h0 ⎠

Y f = Kε n = 548Mpa

F = K f Y f A = 1,647,744 N = 1,647 kN
 Exercise 6

A cold heading operation is performed to produce the head on a steel

nail. The strength coefficient for this steel is 600 MPa, and the
strain hardening exponent is 0.22. Coefficient of friction at the
die-work interface is 0.14. The wire stock out of which the nail is
made is 4.75 mm in diameter. The head is to have a diameter of
9.5 mm and a thickness of 1.6 mm. The final length of the nail is
120 mm.

(a) What length of stock must project out of the die in order to
provide sufficient volume of material for this upsetting operation?

(b) Compute the maximum force that the punch must apply to form
the head in this open-die operation.
 Exercise 6 - Solution

(a) What length of stock out of the die

π
V= D 2f h f = 113.4mm 3
4
because the volume must be the same
π
V = V0 = A0 h0 A0 =
4
D0 = 19.6mm 2 ⇒ h0 = V A0 = 5.78mm

(b) Compute the maximum force

⎛ h0 ⎞
ε = ln⎜ ⎟ = 1.28 Y f = Kε n = 634 MPa
⎝h⎠
π 0.4 μD
Af = D = 70.9mm
2
f
2
K f = 1+ = 1.33
4 h
F = A f K f Y f = 59,8 N
 Exercise 7

A hot upset forging operation is performed in an open die. The

initial size of the workpart is: Do = 25 mm, and ho = 50 mm. The
part is upset to a diameter = 50 mm. The work metal at this
elevated temperature yields at 85 MPa (n = 0). Coefficient of
friction at the die-work interface = 0.40. Determine

(a) final height of the part, and

(b) maximum force in the operation.

 Exercise 7 - Solution

(a) final height of the part

π π
V0 = D h = 24,544mm
2
0 0
3
Af = D 2f = 1963mm 2
4 4
V0 = V f = A f h f ⇒ h f = V f A f = 12.5mm
(b) maximum force in the operation.

⎛ h0 ⎞
ε = ln⎜ ⎟ = 1.39 Y f = Kε n = 85MPa
⎝h⎠
π 0.4 μD
Af = D ⇒ D f = 4 A f π = 50mm
2
f K f = 1+ = 1.64
4 h
F = A f K f Y f = 273,712 N
Extrusion
 Exercise 8

A cylindrical billet that is 100 mm long and 50 mm in diameter is

reduced by indirect (backward) extrusion to a 20 mm diameter.
The die angle is 90°. The Johnson equation has a = 0.8 and b =
1.4, and the flow curve for the work metal has a strength
coefficient of 800 MPa and strain hardening exponent of 0.13.
Determine

(a) extrusion ratio,

(b) true strain (homogeneous deformation),

(c) extrusion strain,

(d) ram pressure, and

(e) ram force.

 Exercise 8 - Solution

2
A0 D
(a ) rx = = = 6.25
0
2
Af D f

(b) ε = ln rx = 1.833
(c) ε x = a + b ln rx = 3.366
Kε n
(d ) Y f = = 766 Mpa ⇒ p = Y f ε x = 2578MPa
n +1
π
(e) A 0 = D02 = 1963mm 2 ⇒ F = pA0 = 5,062,000 N
4
 Exercise 9

An L-shaped structural section is direct extruded from an aluminum

billet in which Lo = 250 mm and Do = 88 mm. Dimensions of the
cross-section are given in Figure. Die angle = 90°. Determine

(a) extrusion ratio,

(b) shape factor, and

(c) length of the extruded section

if the butt remaining in the container
at the end of the ram stroke is 25 mm.
 Exercise 9 - Solution

(a) extrusion ratio,

A0 ⎧ π 2
rx = ⎪ 0
A = D = 6082 .1mm 2

⇒ rx = 5.068
0
Af ⎨ 4
⎪ A f = 2 * (50 *12 ) = 1200mm 2
⎩

(b) shape factor

To determine the die shape factor we need to determine the perimeter
of a circle whose area is equal to that of the extruded cross section:

A f = πR 2f = 1200mm 2 ⇒ R f = A f π = 19.54mm
Cc = 2πR f = 122.8mm
C x = 62 + 50 + 12 + 38 + 50 + 12 = 224mm
 ⎛ Cx ⎞
K x = 0.98 + 0.02⎜⎜ ⎟⎟ = 1.057
⎝ Cc ⎠
(c) length of the extruded section if the butt remaining in the container at
the end of the ram stroke is 25 mm

Total original volume: V0 = A0 L0 = 1,520,531mm

3

⎧
Final volume: ⎪ butt : V 1 = A0 * 25 = 152, 053mm 3

⎨
⎪⎩extrude : V2 = V0 − V1 = 1,368,478mm 3
V2 = A f Les ⇒ Les = V2 A f = 1140.4mm
Drawing
 Exercise 10

A spool of wire has a starting diameter of 2.5 mm. It is drawn through a

die with an opening that is to 2.1 mm. The entrance angle of the die
is 18° degrees. Coefficient of friction at the work-die interface is 0.08.
The work metal has a strength coefficient of 450 MPa and a strain
hardening coefficient of 0.26. The drawing is performed at room
temperature. Determine

(a) area reduction,

(b) draw stress, and

(c) draw force required for the operation.

 Exercise 10 - Solution

(a) area reduction

r=
( A0 − Af )
⎧⎪ A0 = (π 4 )D02 = 4.91mm 2
⇒⎨ ⇒ r = 0.294
⎪⎩ A f = (π 4 )D f = 3.46mm
2 2
A0

(b) draw stress

⎧ A0
⎪ε = ln
Af
= 0.349
⎪
⎪⎪ _ Kε n _
⎛ μ ⎞
⎨ f
Y = = 271 .6 MPa ⇒ σ = Y f ⎜ 1 + ⎟φε = 154.2 MPa
1+ n ⎝ tan α ⎠
d
⎪
⎪φ = 0.88 + 0.12 D LC = 1.31
⎪
⎪⎩
(c) draw force required for the operation.
F = σ d A f = 534.0 N
 Exercise 11

Bar stock of initial diameter = 90 mm is drawn with a draft = 15 mm.

The draw die has an entrance angle = 18°, and the coefficient of
friction at the work-die interface = 0.08. The metal behaves as a
perfectly plastic material with yield stress = 105 MPa. Determine

(a) area reduction,

(b) draw stress,

(c) draw force required for the operation, and

(d) power to perform the operation if exit velocity = 1.0 m/min.

 Exercise 11 - Solution

(a) area reduction

r=
( A 0 − Af )
A0
A0 = (π 4 )D02 = 6361.7 mm 2
D f = D0 − d = 75mm
A f = (π 4 )D 2f = 4417.9mm 2
r = 0.3056
 Exercise 11 - Solution

(b) draw stress,

⎧ A0
⎪ ε = ln = 0.3646
Af
⎪
⎪_
⎪Y f = K = 105MPa
⎪ D0 + D f
⎪ _
⎛ μ ⎞
⎨D = = 82.5mm ⇒ σ d = Y f ⎜1 + ⎟φε = 61.45MPa
⎪ 2 ⎝ tan α ⎠
⎪ D0 − D f
⎪ Lc = = 24.3mm
⎪ 2 sin α
⎪φ = 0.88 + 0.12 D LC = 1.288
⎪⎩
 Exercise 11 - Solution

(c) draw force required for the operation, and

F = σ d A f = 271,475 N = 271kN

(d) power to perform the operation if exit velocity = 1.0 m/min.

Nm Nm
P = Fve = 271,475 = 4524.6 = 4524.6W
min s