ME 310 Homework 4 (10/13/2019)

Prob. 1 (a) Compare and contrast hot rolling and cold rolling. (b) Explain 4 ways to compensate
for roll bending to sure that the product in flat rolling is not crowned.
(c) What is the driving mechanism (i.e. what propels the material forward) in rolling operation.
Also, state 5 factors that influence the magnitude of the roll force, F.

Prob. 2: (a) State and explain 3 factors that influence spread in cogging operations on
long square billets. (b) Why is control of the volume of the blank important in closed-die
forging? (c) State and describe the forging defects

Prob. 3: (a) To what thickness (height) can a solid cylinder of 1020 steel (annealed) that is
25mm in diameter and 50 mm high be forged in a press that can generate a forging force of
0.5MN. Assume no friction between the contact faces of the press and workpiece, and Yf is
constant throughout the forging operation. [Hint: use the table on slide 19 of Lecture Note (h2) to
obtain your Yf ].
(b) Assuming that Yf is not constant, estimate the true stress at the end of the stroke (at the same
final height), using the graph on slide 21 of the same Lecture Note (h2).

Prob. 4: (a) What are the similarities and differences between direct extrusion and drawing.
(b) Explain the different ways by which changing the die angle affects the extrusion
process. (c) State 3 types of extrusion defects and 2 ways to avoid/minimize each defect type.

Prob. 5: (a) Draw a well-labelled diagram of a ‘Draw Die’ and explain the features. (b) A round
wire made of a perfectly plastic material with a yield stress of 30,000psi is being drawn from a
diameter of 0.1 to 0.07 inches. in a draw die of 15. Assuming the coefficient of friction is 0.15,
estimate the drawing force required. [Hint: the die angle must be in radian].