Wuolah Free Manufacturing Processes Exercises

manufacturing-processes-exercise...
emilywarren
Procesos de Fabricación
2º Grado en Ingeniería Mecánica
Escuela Politécnica de Ingeniería de Gijón

Universidad de Oviedo
Reservados todos los derechos.

No se permite la explotación económica ni la transformación de esta obra. Queda permitida la impresión en su totalidad.
Exercises
a64b0469ff35958ef4ab887a898bd50bdfbbe91a-9104820
Reservados todos los derechos. No se permite la explotación económica ni la transformación de esta obra. Queda permitida la impresión en su totalidad.
Zapiens
Block 1 .
1) For tolerance grades of medium quality, in order to balance the cost of
manufacturing of the hole and shaft, the tolerance grade of the shaft
should be:
At least, one tolerance grade better than the hole
2) The iso code system could be applied to:

iameters
↓ and distances between parallel lines
3)In the tolerance frame, what is supposed to be represented on the left box?
T he type of geometrical tolerance. 1 A D
1) What datum is A?
↑ he axis of the small cylinder

5)In the position of the fundamental deviation is h
the upper limit deviation is 8
6) which type of geometrical tolerance should be applied to two cylindrical

surfaces having the same axis, each of them supporting a precision bearing?
coaxiality.
7)The tolerance zone defined for the inclined surface is
The space between two parallel planes a distance o'lmm apart and
inclined so with regard to the datum A.
A theoretical exact dimension

8) ITED)
shall not be associated with tolerances
a) which of the following annotations implies larger diameters in a cylindrical surface?

SOEFI SOHS or SOMS)
10) An iso designation is used for dimensions defining sizes of:
Holes and shafts involved in a fit
117 What does the letter of "mean, when talking about general tolerances classes?
Fine
12) For the same nominal value of the dimension, a higher value in the
tolerance grade means.
A larger tolerance interval
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Procesos de Fabricación
Banco de apuntes de la
I 3) The tolerance tone defined by the geometrical tolerance
of the figure is the space between 2 planes
perp .
to A and parallel to B .
141 The waviness profile contains profile contains those signals whose wavelength
is medium between Lambda -

c and Lambda - f
Is) Which tolerance implies that all of the points of the
top surface should be contained between two parallel
planes 02mm apart ?
The one on the left
161 General tolerances
Apply to those linear and angular dimensions without individual tolerance indications .
171 If the tolerance tones of the two parallel tolerances are
combined ,
the result is :
A rectangular prism
181 Which of the parallelism tolerances constrains the
tolerance tone to be contained between two planes parallel to A and perp to B. .
The one whose value is 012
191 For the same nominal site which sentence is true ?

,
ITG implies better precision that 11-7
201 Which letter enclosed in a circle is used for indicating a projected tolerance tone ?
p
211
According to 150 ,
a hole is :
An internal feature of site ,

cylindrical or not
221 The 150 code system uses lowercase letters for designating :
shafts
231 In a dimensional tolerance stand anted according ISO , the letter indicates . . .
The fundamental deviation
241 The upper limit deviation of a hole diameter is equal to the lower limit deviation
but the corresponding signs are different , the position of the fundamental deviation
would be :
JS
251 which geometrical tolerance is only applied for controlling axes ?
The one on the left
261 what is the mistake in " 0010s A

?
Neither the reference to datum A or the symbol of diameter should be included
271 If the tolerance intervals of the hole and shaft of a fit overlap or if one of them
is contained within the other , then the type of fit is :
transition
281 Which of the following designations corresponds to a shaft basis system ?

-
7-OF 81h7
291 Which type of processes permits to reach lower values for the average roughness ?
machining processes lmecanitadol

301 When the geometric tolerance shown in the figure does not have a atoms ,
it controls
Form
31 ) The type of fit 80558 / is 7 is :
Transition
321 Which geometrical tolerances compels all the points of a l nominally ) planar
surface to be contained between two parallel planes separated 00s apart ?

' '
O 05 O 05
Both of them
337 The application of a selective fit system involves

A reduction of the manufacturing cost and an increase of the verification cost .
341 In which figure the geometric tolerance is controller the
lower planar surface of the step ?
In the 0hL Of the left
35) If the axis of the hole I first row first column ) of

,
actual part was located at from A

'
an so 05mm
and at 12 from B Dart should be

'
05 ,
the
Rejected
361 For implementing an interference fit by thermal expansion
the shaft is cooled
371 The ISO code system uses capital letters for designating
Holes
381 A geometric tolerance of location also restricts
Both the form and orientation of the tolerance feature

391 Indicate the acronym that precedes the name of standards published by
organisms pertaining to the European continent .
'
EN 4 O OS
+ 00s A B C
401 Which indication defines a cylindrical tolerance zone ?
00 0s
'
A
The one below
41 ) Ra represents
Arithmetic mean deviation of the roughness profile
421 which of the geometric tolerances shown is only applied to geometric features ?
The one on the right

431 The amplitude of the tolerance interval depends on :
Both the tolerance grade and the nominal site of the dimension
441 HOW many standard tolerance grades are defined in 150 286 ?
20
451 ☐atoms are needles for controlling

location ,
orientation and run -
out
461 Which geometrical tolerance dos NOT control the location ? n
The one on the middle
471 In a dimensional tolerance the fundamental deviation is the one related to . . .
The limit that is closer to the nominal site .
48 ) which type of fit does correspond to 4013766 ?
Clearance
491 sort the categories of geometrical tolerances from most to least restrictive
location -
orientation -
form
so) what does the indication im DIY ?

A straightness tolerance , any extracted lacto all generating
line on the cylindrical surface shall be contained between two parallel planes
feet apart
'
0 l .
Block 2 .
11 Which process can manufacture a Dart like the one shown ?
Rotary swaging
21 Is there a limit for the Max force that can be applied in drawing ?
Yes , you shouldn't surpass the yield limit Of the metal drawn
3) In which process is mandatory to apply a force in the same direction as that of
the movement of the final section ?

In drawing
4) Which is the main advantage of thread rolling Wrt thread machining ?
Threads are stronger because of favourable grain flow
5) In flashes closed -
die forging ,
an error in the calculation of the volume of the
material can cause
Both : non enclosure of dies / die breakage .

Or ,
void regions in the forged part
6) From which of the continuous casting products is possible to manufacture a
seamless tube ?
The billet
7) In rotary draw bending of tube ,

what is the function of the flexible mandrel ?
To avoid that the tube buckles or folds
81 Which Mill stand would require lower load for the same
reduction ?
The one on the left .
9) what defect presents the sheet metal rolled in the figure ?

wavy edges
101 In the hydroforming of this part ,
which tool performs the function of the die ?
The rubber diaphragm .
111 square dies are used for non -
ferrous materials because
They develop dead -
metal tones that provoke bright surface finish

121 which device is required for extruding a metal seamless tube?
A mandrel
131 which type of extrusion is represented ?

central indirect extrusion
147 which material can be extruded from a tubular shape with a spider die ?
Aluminium
IS) What is the continuous casting product suitable for obtaining a suitable profile?
The bloom
161 From which one of the continuous casting products it is not possible to manufacture
tubes ?
BLOOM
171 which is the appropriate machinery for drawing wire ?
A multi-step bolt block
181 Which type of Mill stand is represented in the figure?

Four -
high stand
191 what is the name of the sheet metal forming process shown ?
Hydroforming
201 Cracks on the outer surface of a bent sheet of metal are more likely to appear
when bending direction is parallel to previous rolling direction
217 Forge is only competitive
At high production rates
221 In a tandem rolling train ,

which should be the most critical parameter ?
The speed at which the strip travels through each roll gap
231 Rolls shall undergo shape changes due to rolling forces . Which of the following
consequences is true?
The rolled strip shall be thicker at its centre
241 After bending ,

hardness varies along the thickness of ④ Sheet plate so that
Material is harder in the tones near the surface
251 which Of the following options would cause this type of residual
stresses on a rotted sheet metal Plate ?
The use of big diameter rolls and High reductions of thickness Dlr pass
261 What is the process represented in the figure?

Impact extrusion
271 Arrange in order the following types of extrusion from lower to greater
friction coefficient between container and billet
Hydrostatic < central indirect < Direct
281 The outer fiber of a bent metal sheet has undergone

Tensional stresses
29 ) what is the name of the

stage required for obtaining the 3rd Shape
from the 2nd one ?
Blocking
301 What is the name of the sheet metal forming process shown in
the figure?
spinning
311 Which condition will cause higher spring back effect ?
High yield stress and low thickness
321 Which pair of rolls would be suitable for obtaining a
sheet of metal band with better flatness ?

The one on the right
331 In deep drawing , which tool prevents the appearance of wrinkles when the
Cup starts to form
Blank holder
341 Where is the neutral fiber located in sheetmetal bending ?

Between the stress free fibre and the-
middle fibre
3s) suppose you are hired to reduce forces in a roll stand . which action would you
suggest ?
Select rolls with smaller diameters
361 In the thread rolling operation represented in the figure which,
elements must rotate during the process ?

Both ,
the workpiece and the rolls
371 In roll forming ,

a higher number of stations implies
A better control of the spring back but an increase in cost
381 What is the name of the process ?
Closed die forging with flash and inserts
391 Characterize the eltect Of flash in closed die forging

It 's positive ,
it is constraining the radial outward flow of the material in the die
401 What is the advantage of hydrostatic extrusion ?

It improves form ability by imparting triaxial compressive stresses .
Block 3.
1) What component is notpresent in an injection mold?
RISOU.
2) In which of the following processes the pattern remains inside the mold
while the molten metal is poured?

Evaporative -
pattern casting.
3)The main defect
in a container producedby extrusion blow molding is
The the partition line of the mold

burr at
4) In which casting process is flash like the one shown
in the figure most likely to appear?

Hot-chamber die casting
5) which casting process does the photo
correspond to?
cold chamber die casting
6) which characteristic is desirable for
not mold design in casting?
large flat areas
7)which is usually the most significantshrinkage steps during the cooling?

solidification shrinkage
of taking the surface finish of the
into account part shown
in the figure, whatis the casting process chosen for its
manufacturing?
sand mold casting
9) which die-casting process is usedwith low-melting-pointalloys?
The not chamber process
10) What in the

is the name of the element figure for
the manufacture of a turbine?
Mockl.
11) In expendable mold/permanent pattern processes, which should be a
proper material for manufacturing the pattern?

wood.
12) Sintering heats compacts to a temperature

Below the melting point of the metal
13) whattype of mold is usedin the casting simulation?

moldmade of steel.
permanent
14) which process would you recommend for casting stainless steel?
ceramic-mold casting
1)What is the name of the yellow element?

core
16) What is the main advantage of a 3-plate mold
when compared to a 2-plate mold?
Automatic separation of parts from runners
17) In thermoforming, a positive mold is
CONUeX.
181IM powder metallurgy, parts in a "green state" are:
At minimum strength
19) What is the process shown in the figure?
Blown film extrusion
20) In a region of the cast part of
the figure the material has
not filled the mold, now

could this problem be avoided?
Increasing the section of the runners
21 Blow film extrusion operates

vertically
22) In plastic extrusion, the rotational component of the melt flow is
removed by passing it through

The breaker plate
23) The process for manufacturing the tubular
workpiece of the figure is called ...
centrifugal casting
24) In rotational molding, the polymer is introduced in the mold as ...
Powder
25) In a sand mold, which is the part that acts as a reservoir of molten
metal?
RISeV.
16) The type of mold shown in the figure is ...
Hof-runner mold.
2) In Hot Isostatic Pressing, the mold is made of...
sheet metal
28) the type of mold shown in the figure is
cold runner mold with 3 plates
29) The injection molding of thermosets, the barrel is
100led.
301 Whatis the name of this thermoforming
variant?
positive process with mechanical pre-stretching
31) which type of pressing is shown in the figure?
single-action pressing with Dunches of separate mov.
32) In thermoforming, for improving the detail and
surface finish of the inner surface (concave part
the bestsolution isto use
a positive mold
33)what process is shown in the picture?
Extrusion blow molding
34) which process can be applied to thermosets?
Reaction -
Injection molding (RIM)

35) In cold isostatic pressing, the fluid thattransmits
the pressure to the mold containing the metallic
Dowder is
LiquiCh.
36) In sand casting, cores should
provide similar behaviour as the mold does.
3)In permanent mold processes, pattern could be made of
pattern is virtual in such type of process.

part of the figure, whaterror has
35) In the cast occured?
Error in the allignment of the cope and drag.
39)In which casting process is the defect of the figure mostlikely?
sand-mold casing.
Block 4.
1) is the name ofthe
What machine shown?
sensitive drill press
2) In face milling of a flat surface, the surface finish is
determinedby:
the tool nose radius and the feed.
3) In a cutting fluid thatis an emulsion of oil andwater, a higher percentage

of oil causes a predominantaction of
Lubrication
4) What is the name of the process shown?

inreading
5) which process is shown in the image?
Traverse cylindricalgrinding
6) Whatis the name of the process
shown in the image?
Parting.
7) which process could correct a slightdeviation in the axis position of a
previously machinedhole?
Boring.
8) The boring operation is carried out in a
Both in the lather and in the milling machine.
9) centerless guiding is appliedto

cylindrical surface
10) in which hole making process the tool has a greater number of cutting
edges?
Rearning.
1) The wear on the rake surface of a cutting tool produces:
A crater.
12) At
high cutting speeds, the greatest percentage of generatedheat in a
chil removal process is dissipatedthrough:

The chip.
13) The grade of a grinding wheel is affectedby :
The strength of the bondmaterial
14) in cylindrical down milling, the underformedchip section for each edge is
maximum
when the edge begins the cutting action.
19) Built-up edge (BUE) appears under:
#ian depths of cut
16) which process is shown in the image?

superfinishing.
17) What is the name of the process shown in the photo?
Boring.
18) In face milling of a flat surface, if the engagement is more than 50%
the undeformed chip section for each edge is maximum
when the edge is in the front

of the cutter according to the feed direction
19) The action of the cutting fluidcan be detrimental to tool life due to
thermal fatique in
MillIng
201 The workpiece reciprocates during
Both, transverse cylindrical and surface grinding.
21) which of the following cutting tool materials has higher tooakness?
HSS
22) which combination of cutting conditions is the most approplate for a
roughing operation?
#an feedrate andhigh depth of cut
23) In cylindrical climb willing, the undeformedchip section cut by each
edge is maximum
when the edge enters into cutting action
right
24) which operation is shownin the image?
Facing.
25which type ofmilling machine is shown?
vertical spindle.
10) Reaming yields
Either cylindrical or conical holes
27) which one of the following processes is adequate for improving the
dimensional accuracy andthe surface finish of a big diameter hole?
Boring
281 which fixture is suitable for clamping NON cylindrical workpieces in the
headstock of a lathe?
4-aW ChOCK
29) which process is shown?
#oning.
30) In face milling of a flatsurface, for the same tool material andinsert
geometry, the operation could be carriedout in less time if the cutting

edge angle of the insert were
10 degrees
Voluntary tasks
Rolling products made of aluminium.
Aluminium is a low-density, light-weighted, easily casted, machined and formed metal,
widely used in the industry and in day to day. Many huge companies, dedicated to the
manufacturing of aluminium products, have emerged in the past years. This metal is
usually processed in the form of rolling products, but can be found as well in the shape of
extrusion, casting, machining…
As in any other metal, aluminium rolled products can be the final manufactured part or
just an intermediate step of the processing. Let’s classify the diﬀerent products we can
obtain from rolling aluminium:
BIBLIOGRAPHY:
Totalmateria: https://www.totalmateria.com/page.aspx?ID=CheckArticle&site=ktn&NM=339
E.P.A.: https://www.epa.gov/eg/aluminum-forming-effluent-guidelines
K.M.C. aluminium: https://kmcaluminium.com/what-are-aluminium-rolled-products/
Gabrian: https://www.gabrian.com/aluminum-rolling-process-overview/
Impol: https://www.impol.com/products/rolled-products/
R.S.C.: https://www.rsc.org/periodic-table/element/13/
aluminium#:~:text=It%20has%20low%20density%2C%20is,and%20the%20sixth%20most%20du
ctile.
- AIDA NÚÑEZ FERNÁNDEZ

ING. 09/10/2022
1. Intro to manufacturing processes
Nominal size =
40
clearance: Tmax*= 92nm Jmin*=24Mm
↑olerance grades: span* = Jmax* -
Twin *IT+t
Span* = 92-14= 682T+t
Look at table 1:
1) Look for the interval where our nominal size (%) is contained ->
Row &
2) In that row look for. I consecutive values which added up are the closest but Espan* -
15,39
is and sabe2s +39=6460

tishafts) chose 158, it7
-> -
we
so now we're left with 2 options: 39(ITO) IS (it7) Capital letters for holes
More economic when IT = it + 1 25 (1T7) 39 lits) and otherwise for shafts
Right now, the info we have is: 40 8/7
ole-Basis fit system

#
In the hole-basis system we write an it before the value and

+ 0'049 SO such that T EX NSH(IT) NS T
4
0H8 =
400 also, we take FF =
0 = ES - -> =
pply
*
the specifications:
Tmax =
Es-ei=Jmax* -
39-1i = 92-11- 93
-> min: El-eS = Tminx- 0 -
e9 = 14 -
19-24
Look table 3(shafts):
1) Look for the row of our nominal size (40) ->

ROW8
2) look for the column of the closest is escomputed (= - 24) -f (es =- 15)
t () = -
l) -
25 = -
15 -
2 - i = -
19 -
15 =- S8
letter obtained
NS it ->
40+7
check the original specifications:
↑ max Jmax* - 29-1-50) = 89=92r
Jmin: Jmin*-0-1-15) = 19114/
Final answer: Ns Holeletter It/shaftletter it ->

40H0/f7
n6
7) /77-Nominal size: 70 its and IT7
F
or the shaft.
Looking at table 1: intersection between 70 and IT - += 19
we use letter h When es =
0 such that t =
ex -
ei →
NS hit =
Ns
%
ex ei -19 %
t ei t get : 70h6 70 019
'
we
= -
→ = -
= → =
For the hole:
looking at table 1 : intersection between 70 and 11-7 →

30 =T
looking at table 2 : intersection between 70 and 2- →

ES =
-210+111-7=-210+11 =
-199
702-7--70=8%99 ¥I
1- = EI -
ES →
ES =
EI -
T = -
199 -30 =
-229 →
we get INS )
A- Max =
es -
EI =
0 -
l 229 )
- =
229µm
Am in = ei -
Es = -
19-1-1991 =
180µm
*
Hole : so H8 minimum interference Amin O IS Shaft ?
'
= =
,
,
The hole is given :

looking at table 1 : intersection between so and 11-8 →
1- = 39µm
◦ 39
Hole basis fit system :
-
EI = and T =
ES -
Et = ES =
39µm →
so
For the shaft :
In clearance : IT = it + 1 → it = IT -7 = IT 8 -
t =
it 7
*
Amin = ei -
Es ≥ Amin → ei -
39 ≥ 150 →
ei ≥ 189
Looking at table 3 : look for the closest ei 2189 in row so is

zb with ei = 242
looking at table 1 : intersection between so and it7- →

t = 2s
t =
es -
et → es = ttei =
25+242 =
267
502-67=-50++8 :{fit
* *
Shaft =
52kt ,
hole ? Clearance : Jm in = 100 Imax = 200
For the given shaft :
looking at table 1: intersection between 52 and it 7 →

t =
30
looking at table 3 : intersection between S2 and K →

ei = 2
t =
es -
ei →
30 =
es -
2 →
es =
32
For the desired hole :
we take IT = it + 1 = 7+7 = IT 8
Looking at table 1 : intersection between S2 and IT 8 →

1- =
46
Jmax = ES -
ei ≤ Imax* →
ES -
2 ≤ 200 →
ES ≤ 202
*
5min = Et -
es ≥ Jm in →
El -
32 ≥ 100 → El ± 132
Looking at table 2 : look for the closest El 2132 in row 52 To

C With El = 140
Check ES condition : 1- =
ES -
Et → 46 = E 's -140 →
ES =
186 ≤ 202 ✓
52C 8=-528%8
*
checking both conditions →

Jmax = ES ei
- =
180-2 ≤ Imax = 200
-5min ?
* *
Remember to check conditions .
: Imax . . .
•
JM in = Et -
es = 140-32 ≥ -1min = 100
* *
NS = 30 Clearance : 5min = SO Jmax = 85 11-7 Max 11-8 Max Hole basis
-
First of all we check the span condition in the best case :
* * *
span = JMAK _
-1min ≥ Ttt →
8s -
SO ≠ 33+21 →
357-54
Table 1 : intersection between 30 and 11-8 →
33
Table 1 : intersection between 30 and it 7- → 21

*
When the span Cona .
doesn't check we have to design a selective fit system
,
selective fit system by steps :

1) Determine the number of families
Ttt
Families Max
*
-5min*
=
§¥ =
I
'
54 →
round up → 2 families
2) Divide the known component into families for the most accurate case 11T mail.it Max)
known component →
hole be hole basis system -
,
so El = and Es -5=01033
3050010
0%33=0 01g
033
'
•
Family 1 :
3048=-30 →
•
Family 2: 30++80%33
3) Determine the families for the unknown component using Jmax and 5min
Family 1 Jmax ei ≤ *
16 ei 8s ei -69
{ 30=8%9
: =
ES -
Jmax → -
≤ → ≥
#
5min = EI -
es min → 0 -
es ≥ so →
es ≤ -
so
Family 2 ei ei
/
: Imax = 33 ≤ 8s ≥ S2
30=8%42
-
→ -
Jmin = 16 -
es ≥ so →
es ≤ -
34
4) Check manufacturing conditions ltmax / Tmax)

es family 2
For the shaft → (Fam Ii 14T +
Family 2) →
NS ei family 1
→
30--0%639"
t et O 069 )
'
O 034
'
= es -
= -
-
I -
= 0035
Looking at table 1 : intersection between 30 and it 7 →

tmax = O 021
'
+ Max ≤ t →
21 ≤ 3s ✓
S) Express the unknown component in ISO lei ≥ ei all families ) and final solution table
looking at table 3 : closest value ei ≥ -01069 →

d with ei = -
O' 06s →
3007
Family I I
Holes 300+0016 30++8%78

Shafts 30--090%9 30--8%4
*
Hole : 30ps Interference : Amin * =
O' 015 A Max =
O' 045 Shaft ?
Hole (given) :
looking at table 1 : intersection between 30 and ITS is -1=9
looking at table 2 : intersection between 30 and P →

ES =
-22+3=-19
F- ES -
EI → 9 =
-19 -
El →
EI = -
28
Shaft I wanted) :
In interference : it = IT +7 = 5+7 =
it 6
Looking at table 1: intersection between 30 and it 6 → 1- = 13
A Max = es -
EI ≤ Ama ✗ * → es -
I -281<-45 →
es ≤ 17
I -191
*
Amin = ei -
Es ≤ Amin →
ei -
≤ IS →
ei ≤ -4
looking at table 3 : closest value ei ≥ -

4 in the row 30 →
j with ei = -4
t = es -
ei →
13 = es -
1- 4) →
es = 9 301-6
☆
For 30 MS 1 interference) : 30=88,9 ,
looking at table 1 →
intersection between 30 and ITS →
1- = 9
looking at table 2 → intersection between 30 and M →

ES = -8+3=-5
1- =
ES -
Et →
9 = -
s -
EI →
EI = -
s -
9 = -
14
For 301=86 1 clearance) : 3018%42

intersection between 30 and 11-6 →
1- =
13
looking at table 2
→
intersection between 30 and FG →
EI =
12
1- = ES Et
→
13 =
ES 12 → ES 25 se Sabe ?
- -
=
Como
For 3057 I ? ) : 301883,32 us

transition fit as
intersection between 30 and 11-7 → 1- = 21
intersection between 30 and J →
ES =
12
1- = ES -
Et → 21 =
12 -
El →
EI = -
* *
NS =
4s Fit 1 : 451=9 Jma✗ = O' 07 Fit 2 : 45N 10 AM ax =
'
O 156
* * *
span = Ama ✗ + Jmax ≥ Ttt
For fit 1 :
looking at table 1 : interference between 4S and 11-9 → 1- = 62
looking at table 2 : interference between 4S and F →

El =
2s
1- =
ES -
Et is
62 = ES -
25 →
ES = 87
*
Imax =
ES -
ei ≤ Imax →
87 -
ei ≤ 70 → ei ≥ 17
For fit 2
'
looking at table 1 : interference between 4S and 11-10 → 1=-100
looking at table 2 : interference between 4S and N →

ES =
1- =
EX -
El is
El = -
T .= -100
*
A- Max =
es -
El ≤ A Max →
es -
1- 1001 ≤
156 → es =
Sf
1- =
es -
ei =
SG -
17=39
the closest ei ≥ 17 in row 4s →
n with ei = 17
looking at table 1 : interference between 4S and 39 →

it 8
A Max =
es -
El =
Sf -
IS =
31 Amin =
ei -
ES =
17-0=17
s ◦ *
Shaft Hole : 63
'
63h7 c-
'
✗= I 8.10 6 AM in O' 005

-
: =
For the shaft (given) :
looking at table 1 : interference between 63 and it 7 →

-1=30
and h
looking
/
at table 3 : intersection between 63 es →
%
→
63 .
+ = ex -
ei →
ei =
-30
For the hole unknown ) :
' ' d
Looking at table 1 : intersection between 63 and 11-6 →
1- = 19
* ' ' b
Amin = ei -
Es ≥ Amin → -30 -
Es ≥ s → Es ≤ -3s
163=8%3,1
looking at table 2 : closest Es ≤ -3s in row 63 → R with ES =
-3s
,
1- = ES -
Et →
19 = -3s -
EI is El =
-54
For the fit : Dm in ≥

dmax →
NS +
El ≥ NS +
est 11N Siesta AT )
O' 054 163+01 s '

≥ 63+0 134-10-3 AT
'
83 / 8.10 AT 62 946 ≥ 63+1

-
'
-
+ . . →
1- room
'
AT ≤ 47 6°C =
20°C
§
-
'
AT TF To TF -47 6 TF -20 ≤ 4716 27 6°C

'
= -
= -
T room ≤ → -
→ TF ≤ -
*
Region 1 : shaft : 6047 A Max = 130 Amin
* =
10
* *
Region 2: Jmax =
210 5min = 90
For the given hole :
Looking at table 1 : intersection between 60 and it 7 →

1- =
30
looking at table 3 : intersection between 60 and y →

ei =
144
1- =
es -
ei →
30 =
es -144 →
es =
174
si lees esto me debes un besito

For region 1:
* * *
span = A Max -
Amin ≥ Ttt →
130-10>-1-+30 →
1- ≤ 90
looking at table 1 : closest value 1- ≤ 90 in row 60 →

11-9 With 1=-74
*
A- Max = es -
Et ≤ A-Max →
174 -
El ≤ 130 → El ≥ 44
looking at table 2 : closest valve El ≥ 44 in row 60 →

E with EI = 60
F- ES -
Et → 74 = ES -
60 →
ES = 134
Check : A Max =
17-4-60 ≤ 130 AM in = 144 -
134 ≥ 10 ✓
For region 2 : now our data is the hole of Region 1 : 601--9=60++8
*
span
*
=
Imax _
-2min
* ≥ Ttt →
210 -90 ≥ 74 + t →
t ≤ 46
looking at table 1 : closest value t≤ 46 in row 60 →

it 8 with 1- = 46
*
We cannot find this
Imax = ES -
ei ≤ Imax →
134 -
ei ≤ 210 → ei ≥ -7g
→
Value at table 3 , so we
*
JM in = Et -
es ≥ -1min →
60 -
es ≥ go →
es ≤ -30 compute the other
looking at table 3 : closest valve es ≤ -30 in row 60 →

f with es =
-30
t =
es -
ei →
46 = -30 -
ei →
ei = -76
Check : Jmax =
134+76 ≤ 210 Jmin =
60+30=90 ✓
The final shaft is : 601-8 Remember to always check conditions !
* *
Shaft : 68M 7 Interference : Amin =
20 A Max =
/ SO
For the shaft (given ) :
looking at table 1 : intersection between 68 and it 7 →

t = 30
looking at table 3 : intersection between 68 and m → ei =

11
t =
es -
ei →
30 =
es -
11 → es =
41
For the hole unknown ) :
A Max =
es -
El ≤ A- Max
*
→
41 -
El ≤ I so →
El ≥ -109 →
Not i in table 2 , compote Est
*
min= ei-ES
A
= Amin -11-E):10 -
F)=-9
looking at table 2: Closest value ES-9 in row 60 - N with -

11+D =
-11 + 16 = 5
* *
S an* = Amax -
Amin = Tt -190-10=T +30 -T=100
1T9T= 71
Looking at table 1: closest value + (100 invol60 ->
T ES E) -
74 S E1 -
E1 69
=
-
=
- =-
Check: Amin = 11 -
5 = 10 Amax 41 =
+ 89=150 U
-
0'00S
- 8M9 = 60-01069
NS 170
=
Interference: Amin* =
100 bearing: U
Temperature change cheating of axe): TF1 = 1130 TF2 = 93°C
Xaxie = 12.10-01" xbearing = 15.10-01-
For the bearing:

n -
es = 0h always means es =0
t = l) -
ei >
-
ei = -
t
or the axle:
=
*
MinT = INStEl) 17+xITF1 -
Toll = NS -> (120+ E1)(1 + 12.10-0(113-10)) = 178
↓
maxT = (NS +ES) (7 + xITF2 Toll -
= NS -
+ES((1+
(120 12.18- 193-101) = 120
solving both equations, we get: Es=-010s and E1 = -
0138
looking at table 2: closest value ES-10S inrow 110 -
With ES =-144
For the bearing again: if we look for this value in tables, we get a letter
Amin =
ei -
ES: Amin* -> ei+144=100 -

111-44& different from h
t = xi 44 which is the data given so we don't

=
-
looking at table 1: closest value as in row 110-i6
For the axle again :
IT = it + I =
6+1 = 11-7
120 U 71h6
*
Transition fit clearance: Jmax
*
=
17 Interference: Ama✗ =
IS
' *
10-0 shaft : 80ps
•
✗ =
20 -
c- clearance : Jmax 1- =
35
Clearance : DT shaft = 08 ATHole Interference : DTshaft =

ATHole
For the shaft ( given) :
looking at table 1 : intersection between 80 and its →

t =
13
looking at table 3 : intersection between 80 and p →

ei =
32
+ = ls -
ei →
13 =
es -32 →
es =
45
For the hole Unknown) :
* * * ≥
span =
Jma✗ + A Max Ttt → 17 + IS ≥ 1-1-13 → T ≤ 19

11-6
Jmax = ES -
ei ≤ Jmax* →
ES -32 ≤ 17 →
ES ≤ 49 →
Not in the table
*
A- Max =
es -
Et ≤ Ama✗ → 45 -
El ≤ IS →
El ≥ 30
Looking at table 2 : closest Uawe El ≥ 30 in row 80 →

F with El =
30
For the clearance :

*
≤ d mint
y
Dmaxt -
d mint Imax t →
Dmaxt - ≤ 3s
Dmaxt =
( NS + ES) 17 + ✗ DTHO let =
80 049 ( 1+20-10-6
'
-
AT# Ole)
ei ) 11 AT shaft) 03211+20.10-6 O 6 ATH Ole)

' '
d mint =
1ns + + ✗
=
80 .
solving the equations for the 3 equations -3 Unknowns :
28 125 AT Hole 48 125

'
DTHO le
'
= →
1- Hole F =
+20 =
⑤ Shaft O' 6 AT Hole 875 shaft F AT shaft +20=36875

'
☐ = =
16 →
1- =
a) 40kg
For NS = 40 ,
11-7 and hole -
basis system →
4011-7
looking at table 1: intersection between 40 and 11-7 →

1- = 2s
Hole -
basis system : El = → F- ES -
Et H Always means 1--1=0
ES = 25
For the shaft :

* * *
span = Jmax + A Max ≥ Ttt →

23+18 ± 2s + t → t ≤ 16

its with f- 16
Jmax = ES -
ei ≤ Jmax * →
2s -
ei ≤ 23 → ei ≥ 2
looking at table 3 : closest value ei ≥2 in row 40 → k with ei = 2
b) Dmint ≥ dmaxt
☐ mint
dmaxt
=
=
( NS + EI ) 17 + ✗ ATHO 6)
(Nst es) (7 + ✗ AT
= (40+0) 11+1
'
2. 10
shaft =/ 40+0 018 ) 17+112.10-5 IT shaft F- 201)

'
-
s
(25-201)=4010024
/
get Tshattf 48
'
soloing we : = -
12
temperature :
*
Shaft : soft Soc -90°C Clearance : Jmax 1- =
130 Jm in
*
1- =
30
-10°
' 1
C-
◦
17-10-6
◦
✗A =
10 ✗B = C-
For the shaft cgiuen) :
looking at table 1 : intersection between so and it 7 →

1- =
2s
looking at table 3 : intersection between so and f → es = -2s
t =
es -
ei →
2s =
-2s -
ei →
ei =
-
so
*
☐ MAXT -
d mint ≤ JMAK T
( NS + ES ) 11 + 20 )) =/SO ES) ( 11-17-10 IS -201)

•
Dmaxti ITI
{
-
= ✗B -
+
Es ≤ oiogg
dmintl =
( hstli ) ( 7 + ✗A 11-1-2011 =
ISO -
O' 05111+10-10
-
•
IS -201)
ES) ( 7 11-2-2011 ES) ( 11-17-10 190-2011

"
Dmaxtz (so
{ Eg
= INS + + ✗B = +
dMINTZ = ( us + lil 11 + ✗A 11-2-2011 =

150 -
O' 05111 + 10-10-6190 -201)
D. mint -
dmaxt ≥ -1min * T
( NSTEI ) 11 + ✗ B 11-1-20 )) =/SO ) ( 11-17-10

•
IS -201)
-
f
D mint , = + EI
e , ≥ go ,
DMAXTI 1ns + est 11 ✗A 11-1-2011 150 O' 025111+10-10
•
IS -201) -
-
= =
+
-
( NSTEI ) ( It ✗ B 11-2-20 )) (50+1--1) "

190-2011
/
1) Mintz = = 11+17 -10
E , ≥ -0,01g
DMAXTZ =
1ns + est 11 + ✗A 11-1-2011 =
150-0025111 + 10-10-6190 -201)
we take the more restrictive case →

ES ≤ O' OSS and El ≥ 0101
IT -
_
it + 7 =
it 7 +1 =/ 1-8
looking at table 1 : intersection between so and 11-8 → T =

39
looking at table 2 : closest value El ≥ to in row so →

FG with El = IS
1- = ES -
Et →
39 = IS -
IS → ES = 54 ≤ 0
'
OSS ✓
SO 1=6-8
2. Plastic deformation processes
rolling.
no c'smm ht 23mm D = 140 2- 408 + 50
w=l00MMAc-t =1-ww
=
=
c E -
1
=
-
5 008
=
b) True strain=9F =
In (EE) =
In (5,
1 =
010834
Truestraint aF-goas
wecondidono previousdeformation do=0aF
=
touestrain
2)Flow stress =
5 = 402+ 50 -
50 =
402 + s0= SO daN/mm2
9 = 409F+ S0 =
40.0'0034 + 50 =
S3'34daN/mm2
d)p JLW
= = 5166470.012x1000:aN =
193331 daN
150 -
5e/nty) + (SF -
f(x) 50 93'34 +
3
ex) xs'68
=
-
2
L = xk(no MF) x140/2(2's -2

-
= =
R A
4 Ah
-
(89x R
=
1
=
-
=
1-
AH 2'5 -2'3
x arcos
=
(1-51 =
arcos 11-140 1 =
31060
·anaon
1= R. SiNX= 70 "SIM 3'060= 3'74
ut to avoid all these computations we can

B similify:
LFxk(no-ht)
elyNOP.EFlay3glYYtOx OrYMMYE =3blIJOCIaNMd

which is much easier
T = ae
335x703
-
9 At the neutral point un wR 0'242

=
=
=
COS XN = R-nF=y-hNj
R
-
hF
-
hN hF =
+ D(1 -
c8SXN) =
23 + 140(1 -
c0509) 22 =
continuity equation: ONAN= UFAF -

UF =
UN = wNE =
0'242 E=0'224
w=100mm no = 2'smm ht 23mm =
D =
140mm
9 =
40.9+50 sentry = 15'7 Sexit =
7'US
a) Friction increment = 18% P?

50 4020
=
+ 50 =
S0
SF = 402F+ 50 = 40 In () +
so = + 50
401(k) =
9334
SF Sexit 50 15'7 33'34-7'US
- so-Sentry
+ +
daN/mm2
-
-
39'9
=
=
2 2
↑
5x (x
=
w = 5xxR(ho UF) - x
w 39'9(140/2(2's -1'3)x100
=
= 14929'21 daN
103N
nOFNILPpII'L'YPaCalLH-IEEICOOCIAN's"EcaNFEEICO'NEsMeEIs w
w=100mm no =
2's ht =
1'3 D = 140 N =
33rDM
9= 40.3+SOdaN, MM2 centry = 15'7 Sexit= 7'09 c=1.2.18's MMP/N
Now, we're considering elastic deformation
-
his deformation causes a
he
=
-
*
y + 9 eater than the one
e. rr
intended
To avoid this issue, we get a greater area of contact: 1' L-oL'= Lk(no-hF
the new radius is valid only for the deformed region

·
1
=
M(no UF)
-
After that, the original radius is recovered (as it's elastic deformation)(R">R)
Hertz theory: R
=
R(1 + (
a) 50 4050 +
=
50 =
50
S= 402F+50
=
=
40in +
50 =
40 In +
s03
5 = 5334
SF -fexit 15'7 5334-7'8S
=so-Centro,
50 - +
daN/mm
-
=
2
=>
39'9 3
R R(1 "nF" * ( need to compute in and in to compute

-we
1) +
no
=
2) p' = 5" ('w =

JXR'(ho-hFlw p. To solve this, we have to iterate starting
with B= R
·
Iteration 1 -
R'0 = R 140/1
=
=
70
Jc/Ro' 39'9(70(2's -2'3):100

↑
p'o =
(no UF)W
-
=
=
14916'S
·
Iteration 2 -
R1 = R(1+nt" 1 7011+10%-14916 =... =
↓ p'i = JXR:(ho -hF) w 39'97R:(2's-1'3)

=
:
100 =
15500'so
we can repeat as many times as we want, results will become closing to

eachother, converging on the real value:
Iteration R P
D 70 14976's b) using" "for the deformation consideration
I 76'27 15500's PWR'=1"Tww =

P'L'W
2 6'54
7 15608'6 =
136098+76'36(1) -
73)+. +335
3 6'ss
7 19309' =
19189W=1'92kW
a) we have the same problem we had in part al:

need for that we require R and viceversa
we want
PFrc,for which we p and
R R(1 hF**(
I
1) +
no
=
2) p' = 5 :
('x w =
JXR'(ho-hF)W Pfric' = 18849'7daN
3)Prric'= 1'2xp1
d) PWRfric' =
10849'7+2/76'5811's -23) + 1335
= 1S40W = 2'skw
Reducing the same him two different cases doesn't require the same power, the second
is always going to need more power due to the hardening of the material. For that,
various steps
instead of dividing the process in with same Ah, we take advantage of
he
t
PWRmax:
no =
smm -> SOOMM ProRmax=600kW = 300mm
* n = 7SUDM
9 402 + 48 n+ 2mm Number of

passes?
=
=
Pass no 1:
So =
40.40 + 40 = 40 to
20 =
0
5
=
40.91 40.1n() 48
+ 40 =
+
a in() In()
= =
50 S1
40 40(n(6/h1) 4) 40+20In (7) daN, mm2+
+
+
52 =
=
=
L RSinx
=
=
xRAh =
<R(no 1) - 1 30012(6-his
=
MM
Pwk = 51-w --
000000 = 140+10in/fill(1300/216-h1)12300.7sn win ta
solving the equation: h1 3'90mm-h= 2 mm need more passes
= -
=
we
Pass no 2:
5= 40(1 +
40(5a)
40 =
+
48 33in(E)
=
9 40.92 = +
40 40.14(π) 48
=
+ 33 40 In 2
= +
48 se =
40(n((38) +
40
) in(t) in()
x In()
= +
in (i) in( =
= =
9 + 52
80 4814(6.6/39h1)
40 18In(53n
+
-= daN
/MM:
=
=
Se
+
2 2
xz =
xR(no x2) -
=
x388/216-herum
PWRmax = 5(:ww -600000 = m) N300/2(3'9-hill"500.7s,ON,M
(40+101n5
solving the equation: m 2'38 >h=
=
=
2 ->
We need another pass
↑
ass n' 3:
Repeating the same process we get us = 1.25 <hF 2 =

-
no more passes needed
once we get the number of passes, we compute the PWRF <ProRmax needed for UF
PWR(hF = 2) 5313" =
w = 140 +20(n(2(38)) (2/300121238-211".300. 7s5=109997192

1) PWRMaX: 6-3'9 2) PWRMaX: 3'9-2'38 3)PWR=189992192: 2'38-2
hF =
1100-12). "
no= 2's mm = 200mm PwRmax =
10000 n= 100rpm
9 39.2 + 48 sentry 15 Sexit=35 Sentry 15 Sexit: 35 RY
=
= =
no 2's /0'88
=
= 2'84
50 35.810 + 40 48 when we consider tensile stress at the

=
=
S1 33.91
=
+ 40 =
35.0'12+48=44'2 entry and the exit (entry, sexit), we compute:
a In(t) In(5) 0'12

= =
=
sentry) (61 5exit) (442-35)

=1so (48 25)
- + -
- +
3 12'l
=
=
2 2
183MM
2'))1.100.1005
1 ON
PWR
=
5kw -
20000 =1211-aN.(R(2.84 -
solving the equation: 1 = 132'12mm
Remember that units must always coincide at both sides of the =
183MM
kgm(c M--
w 5
=
=
=
as we want the resultinmm, we have to our "
+mc-mumm" 5.
rack
We could have also change the units of the
width tom and obtained the result in m instead of rum
a) no = 1100 -
38) /.hi no =
3 mm 2100 mm
-
D 3somm
=
9 = 409+50 No friction PC
n=0'7.no 0'7.3=1'1mm
=
90 =
4050 + 50 = S0
x=4091 + s0 = 40.1n +
s0 = 40. In 111 +
50= 64
5 t' 6.64=S7daN, mm
=
=
4= 51L1 = 97.4350/213-2'1) .
2100 2102223
=
daN
n = (100 -
15)%. he
n2 0'8S. h1
=
= 0'89.2'1 = 1'78S
Se 40.92
=
+
50 40.1n+
=
+
50 40.In8
=
+
50 788
=
5 751=50'0
= =
67'4 daN/mm
↑z JLen 67'4.1350/212'1-1'70s).
= =
2100 =
1050000 daN
b) n =
300rpm no 1100 =
-
301..Ul X?
(P-121 (175-3" 121
-
x = arcos arcos
=
=
4'110
n1 = (108-191%. Uz
179 -
211 -
11785/2
x arcos
=
( 17S 1 =
2430
2) no =
1100 -
301%.Ul
↓175.0'9
PWR = 5-w p.Ew.n 210723X3005.x=S922kW
= =
n1 = (108-191%. Uz
175.0'BS
Pzw.n 30050.x=24S1Lkw
1)
Pwkc 1050000
=
-
=
100mm 9 403 48
n 88%.
+
=
= =
a) An approximation of the forces deduced from the consumed power can sometimes
differ significantly from the real value. This is for both: the friction consideration
and the deformation of the rolls.
-0 40.2
=
+ 48 40
=
81 40.21
=
40 + 48.In()
= + 40 40.1n(+)
=
+
40 =
56122
40 + 562
5 (31
=
=
2
=
48'1l daN/mm or the
#
R'formula, c is a given
constant
P 5..11.
=
1
=
5,. xR(no h1). -
W1 = 48'11 + 15016-4) 100 = 107377'23 daN
↑
FRICTION =
P1 = p1 x 11+ fuction) . =
107S77'13(1+ 0'21=129092'68 caw
18-9.
n, t
129092'68
5n)
21.
R B(1=
+ -
m R,(
=
+ 25011
=
+ 6-4 100 ( =
253'38mm
b) Tension of the roll introduces El resultado No coincide,
40In(( 40 40(n(5)40 40
deberia tomar 53 =53 en
67'72
I
Se 40.92 + + = + =
53:
=
=
waarde arnasisique
+67'72=61'97daN, mm
66'21
5 2 = =
sin car el resultado.
33 40.83 40 40In() 40
=
+ 401n(s) =
+ = + 40 75016=
53
= -
5 7137-61197
=
67172 75'01
3 253
+
+Is-sexitiesEdaNs mnindexit
6 9'4
= =
151-sentry)
3 =
2
+ be it's tension introduced
PWR2=Er.CommWiM6777+SexitaNN"27S(4-31m.2-100m m
x
2
=
1105
↑ CaN
&exit = 19S81N/ M2 x
TON
X
COMMI
C) Neutralpoint
atoqorafenyitn, 300 mm
x in
en 4.24m/s
=
nN hF D(7
= +
-c0sN) 2's 600(1 -10s0(9) 2's4mm

= + =
continuity equation:oF on*

=
4.24x
=
-
54 4.3/M/s
=
=150 no 0 =
UF 4 =
11 310
=
R2 = 350 45daN/MMZ
S=
a) Pmax 883.p =
hi?
As S t->
=
5 5 45
= =
P 5(w 454m(no
=
=
-
n) -
p (7
=
(p 115 454R(no -n)

+
=
+
POLD 1'/5
=
4S(R1(h0
x -
hF) 1'19
=
454320(6 4).
+ -
190 196377144
=
Pax T. MaX.POLD 0'8.196377'44=1S7101'95 daN

=
=
PSTANDI 1.19 +454R1 (h0-hi)W Pmax ->

1S7101'95 1115.45 4320(6-hi). 150 n 4.72
= =
=
=
-
PSTAND2 1'/S+4S/R2 (h1 -hF)W Pmax - 157101'95 115.454390(h)-4).150 -

h 5'17
=
= =
h(f(4'72,517) w, estamal, has que tomarotrav?
b) h1 4172 2 =
5'17
+
4'95
=
mm v 300mn
=
PWR?Wi?Wr?
w/R-W'=sO(300minxmolinosmmy/scomm-lsosraces
w
=
rad
WR2 =1300 ford/BSoveEll"OsradIs e m 14.2 D

wz -
=
=
change of units rm -m
↑
WR =
PWRI + PWR2 =
330459+367539=697'997kW
PNR1 =
1.fric 5WIWL1 =
1.fric d andclawto
bereduced
5wIW.R. (no-hi a in
PWR1 1'19.43.12675.158.31016-4'95) 338459W

=
rac =
PWR2 =
1.fric JW2 WLC =
1.fric Jwcw.Rz(h1 -hc
rac
PWR2 =
5.150.330(49)
1'13.43.1424 -4) =
367539W
300 no 1'S nF 0'0=0.03 D= 150 n 3VOrpMl

=
= =
=
9 = 392+40daN, mm2 Sexits =

13 Sentoye =
17
a) p? M? PWR? So-Sentry + s. -Sexit
b
-
80 =
39.50 40 48 S, 2
=
S1 =39.a1 +4o=BSTUCtolto ess.In-coTE300

40 - 17 + 62
- 13
36
=
= 1010 47s claw
=j.frietxp=1..101.824175-121229'EclaepinsozON.m
P
↓ R(no
PE hF)
-
M P
= =
PWR 5 L" WW P.L.W
=
=
=12(229'7.2/150/2(1'5- 0.8). 300183mm 43/kW
=
From the M formula we can as well deduce that PWR 1. M.W

=
b) R R(1
=
51
+
125(1 115-08
=
+
21. 10-5
(2/229.7) 125'52mm
=
R' 112.36 4128'S1(1'S -hF).300 = 0'800mm

=
p 1 2.5, 1 (no -hF)W -12/229'7 = - hF
hF 1.5 W 1000 R 150 C 211. 18 5 Pmax 600000

-
= =
=
=
=
S1 30.8 20
= +
S2 4009/2
=
J.frc 1 '2
=
no? R,?
=- - i-t
20+ 30(n)31
Material 1:
+ 20
30.2/0 5 285
35
50 10 20
= + = =
31 30.91 10
= +
30.1n(45)
=
+
10 20
= 1s(u(h0 / 1s)
+
p1 1 =
2.5..L.W =1'2(70 15(4)(1s0(h0 -1's), 1000
+
pmax =800000
=
no 3'196
=
mm
Ri R(1 =
+
5h*1 180(7
=
31075.500000) 151'1l
+
1000
=
mm
Material 2:
4029/1 40(n(40/15/2 (40, is)/2
oooopu-i5iro
40
40((73)x)5 1851
50 = =
+
In
20 289
=
2
=
+
=
S1 4829/2 402
=
in
(49)/2(1/150(h0 -1's). 1000 pmax
=
000000
=
no 2'32mm
=
2 1.10-5,500,000
1000 Issis m
2 steps w 800mm
=
ho =3 h=2's no 2 =
1 300
=
DB 450
=
W. 98rpM PWR 1 277667 Wi =

8OrDM PWR2 272050
=
= =
a)s ac b = +
plastic behaviour?
Step 1:
a)
Pi-zin.S'."-olnsblinRe
Step
2: =tm ·5.12 1800's. x.8(aln b).
=
+
12
(2) PWR2 (tn w

=
-
272050 =1500s.001aln b)1'2
+
500's X.U8
Now we have
a system with equations (1) (2) and 2 unknowns:a, b
solving the system:a 17's1 andb 52'0s

= =
5 27'512 52'05
=
No coincide,
revisar
W
=
810 h0=18 D 292

=
B 680
=
P 131325
=
w = 109
Sentry= 0 Sexit 0'88SKN/MM

=
1=899m t?5 =
198 90803
+
50 290 9800'3 250
3
=
+ =
1 0n 104N
=
810.3
+
5 250
= +
909,03 =
250 +
90.1n)
90/n(" 0/hF)0'3-8's
5
so
=
-
Sentry+S1-sexit
2
250
=
-
0 150
+
+
2 = 246 4SIn(00'3
+
p 5,(w
=
-
131325 246
=
+
45(n) 80s oN 4* (1.8 -
UF).810
hF 1.78 mm
=
IS
PURESICWWRU:13132SLOTOPommmylos
PWR 5, L=WW P(W
=
=
131325.2)"
=
(18-1'795). 109 x m =
12230's
PWR PV =
p.5
= -
12230'15 131325.
=
-95 -
t 74625
=
El resultado no
coincide, no si
queestimal
W 720 no=1'8 HF =
1'S D =350 DB 580 PWR 50000
= =
u + (30,70) Pmax=200tons 200 1000 -

1ton 1.10 "N
=
=
S 30 205 7000kg in coming 1:7850kg/m3 F?

=
+
equation:A=IV L
M
continuity 0A0-00F=Fwh
= =
7800/120.80)
720 . 8'707m/s
10-3. 1.5. 10-3
=
OF =
ON WR
=
->
In this case, as the neutral pointis at the end:F 0N 8.787 =
=
w UN, p 0.707/ (175.10-3)

=
=
4.38
=
rad/s revoin 41'83 rpm -> [30,707
=
/
50000
PWR P(W
=
-> p =WR=H17S(18-1's).Y'30 1575492N< pmax =200000000 /

=
a
win rad/s
when there's so, we use:
50 30 2040 30
33'ss)5
=
+
=
I so sentry) (51 Sexit)

20(n(+)
-
+
-
S 30 209 30 2
=
=
+
+
= =
s0 151 Sexit)
30 133'65 + sexit)
+ +
+
5 =
304(33'65 + 8exit)
2
=
p 5,w)
= -
1975492 =
2
·
720x(75(18 -
1's) -
>
Sexit =
9403) aN
s I
=
=
- F=
Sexit. W.HF =940335.718. 1S =
903547'sUdaN
W = 600mm no =
SO he =
25 same reduction of area in each pass
min number of passes and h at the output of each pass ?

D= 700mm Pmax =
1250 tons 5=30 { +
30
Reduction of area = r = 1- h÷ ,
→
r =
1 -1¥
1-3%4-2 0-178 ,
= =
SF -
I =
30 EF -
I +30=30 In . 11%1+30=30 In 1%-71+30 .
SF =
30 EF +30=30
'
In ᵗh¥ +30=30 .
In % +30 =
5079
ESF / ¥7 )
St -
ST = = 40 4
'
+
is in
Pmax -51W 1250.10.4 40 4 ( hˢ¥ ) I 700121hF- 1- I -600

'
→ = + IS In 2s
Solving : he -1=30
'
42mm
E =
In / %-) =
n × / In Fr ) →
In l I =
n .
In 11¥78) →
n =3 'S 4
n = no of passes →
always round up n =3 'S 4 → 4 passes needed
4 passes : ho →
hi hi →
h2 he is
hs h3 →
hf
we obtained the Max .

no passes In mint with the rmax I obtained from Pmax)
but ,
rmax is not the real reduction so let's compute the real r for the nmin
E =
In 1%7 ) =
nx 11h Fr ) →
In 1%1=4 ✗ In 1 #I →
r' = O' 159
hi
I
hi
'
To
'
r = 1 - →
r =
1- →
O 159
'
= 1- To → hi =
42105
h2 hL
UT
'
7 7-4-2105 hz
'
r = - is
O 159 = → =
3536
r
'
=
7 -
¥2 →
O
'
159 = 1 -
35¥36 →
his =
2973
'
hi hi 36 hrs 29 73
'
no =
SO → =
42105 → = 35 → = →
h4 =
25
W =
200mm ho = 4 he =3 Stress before fracture -=k= 17
OF =
30000 M 1h R = 175 14=1600 NM PWR = 680000
w =
600 rpm same Dh at each rolling pass min number of passes ?
Tresca criteria : stress before fracture = k =

¥
If neutral point is at the end : UN =
OF →
AS ON =
W R
- →
OF =
W -
R
1M
w = 01=112--130000 ¥ 36^0%111175 nxm -103mm ) 478 r¥
✗ =
Check : w =
478 r¥- in ¥rc¥ -4548 rpm wmax
× ✗ = ≤ =
600mm ✓
PWR = M W
. →
680000 = M × 4716 →
µ Max =
1428 NM
check : 14=1428 Nm ≤ Mmax =

1600 Nm ✓
µ=Pn%ˢ =
5.
tiiwwiw É 5. Ew = →
1428=21×34×175 Ah *
200
✗
m
'
'
^d¥N
Solving : Ah = O' 24mm
HF -
ho 4 -3
0=24 round
◦ '
h passes =
Ah
= =
4 17 → -
up →
s passes
NOW adjust the exact Dh for the no of passes : Ah = hᵗn# 4¥ = =

012mm
no 4 ho Ah 4- O 2=318 his =3 4 h4 =3 I hf =3
'
hi
'
h 2--318-012=316
'
= → = - = → → → →
extrusion and drawing.
Do =
70mm DF 8mm =
x 90
=
x 59=
35(daN,mmi)
+
For cross-section
a) True strain at the exit:
27
(0
=
207
+
() (ntT=in 5=in(
=
=
R",* int 2n*7
=
=
2n
=
-8 04s
=
Assume no-previous deformation

b) Reduction ofarea v 1
=
-
) 1
=
-
1.0) 1
=
-
155) =
1
-
(8) 0.36=
c) yield stress the entry10 x12 90)

at =
=
-> 40 520
=
35
+
35
=
daN/mm2
↓) yieldstress 4F Y(9 (F) S9F 3S 5.0.4) 3s 37's
atthe exit = =
=
+ =
+ =
an
elDrawingforcerequireddraw.nscYdS +35.0"4s)
# DF2
eN
817
=
#Draw
+) check breakage condition atthe exit spraw=aW=HD2/4 = Y
817
Atthe exit:sDraWF= ON:#82/4 16'2S
=
daN/MM2 YF 37'2S
=
=
daN/mm: V
9) max reduction of area spraw =/3503 YF Y(9
=
=
SF)
= -
2F?
5 +359F=59F +
35
-
9F 187
=
3F (n Fr
=
r?
->
1107 (nFr
= -
r 0657
=
n) power required PWR =

FDraw (N) x0 (m/s) 817daNAN"Tomn=1364W
=
DF 8MM
=
=
16'5kW
PWR PWRmax= x 409
=
40(daN,mm2
+
0 90m/ min
=
max, initial diameter
computation:FDRAW=E* AF(*yd9 -EF?

=
Fraw=* Ig dOm4s 7000N =

=
FDraw=AF/syd9 151409 +401d9 =

=
401951
17000 16π/209F2 409F)

=
+
N-solving
"
>
the equation:
EF 0 (Not possible) and 9 F 0'4s
=
comprostationscanweawstowsce=se"
comm
1000
Fraw 0'7SFext
x
=
359+40(daN, mm2
=

aboWawIANoalt ENHtooYOU WONETE
I ext
#
K10ts)"
=ots -
>v 1-
=
t = 0
b)sxraw = 13 35aF +
401
=
35
In
40 In (EEs) =
12.95 PaN/mm
eF InF
=
=
In 1 -0'Is
=
in Es
Ao= 250mm: Fext=3000daN n 0'2S
=
Yo = S4daN, mm2
Determine the behaviour of the material
1near: Y = a9 + Yo = a2+S4
Ink/0's)
·ext=ERNT=JGFagtSUdETOOOO S41n ts -a?
+
Ors
solving: a 1079
=
otzsicmmYavg=isdaman
e External stress required (6)
AF =
18'39:137)x2+(172'7-2:137)x/'37)=31'04Mmz
3)8 4
v 1
=
1-506'7=8'94
=
-
s =
Yavg 9F = r)
Yara In ( =
1sIn (50qi) =
40%0daN, mmz
↓o SMM
=
PLRmax= 15km 0 = 2sm/min 6-15490'71daN, mmy

minimum Do
- draw =YF ->(Y(2 9F)d9 =
= Y(9 97)
=
-
15/45-254950'17
2F 1117
=
2F i(F) == in))
=
=
=
1'17
-
-DF 3'34mM
=
comprobation: PwR=ProRmax - when we're given a "max" data,

remember to always check condition
1'17
&I
da=AF.IOHOFC'EFECCsUTEN"OaN=9523W
FDraw =
AF (aFOF
WR= FDraW (NJ. OF

↑
[M/S]
PWR =
9523=PWRmax = 15000w v
same reduction of area in each stage:

E= 0'smm per stage
↓o 4
=
-
D1 4
= -
86 34
=
-
(2 28 =
-
D3 2L
= -
(4 =
1) -
DF 1
=
y =
409 +40 daN, mmz 0 18M/S
=
A,(6,d9 44140525 40.83(5)

2
21
FDraw, = =
A1140z + 404) =
+
1372
=
n (n(Δ0/X1= (n(Y/34)
=
= =
0325
This is for the first stage although results don't match
Fbraw A
=
18s =da =H140. 5

+ +
40.27s) 285 =
eF In(= In(t1" 2'7S =

=
This coincides with the answer sheet but forme it doesn't make sense
Even if we had to compute the total Exaw (not what's in the wording), in
each step the force would be bigger.
PWRI = FDNaW1.01 137'2x10N
=
+ Z0 = 2744W
~
Idk what's with this Tom's the whole process, a stages

wrong
exercise:
↓
o = 25'Smm
Lo=600mmdF1197Y=280901t(N/mM7) YF =
308
-F (9
=
260901197d9 280
=
1 197 =
300 -
+ 9F =13
37 In=
(P0Y D+1) In(P0"(5'SY=
=
1'31 ->
D0 =
49'mm
The result doesn't coincide, in why
roIVE-bDOLxLo- tREPL-FFNdlILO S'S'08ThCo-1618smtes
4. Machining processes
tool life.
The only condition that varies between these 2 tests is cutting speed so,
we can apply simplified Taylor's: v.T =c >
Get and (from the tests:
UB NB
E= UB2
-
interpolate: +
gl+T
-
UBI 10 for 0 = 118

Take t =
Tho -
Smin O's mm-8'2mm
For v =
40c
zomin-smin-o'stamm-o'2mm andt=20 fOUr=118
FOOU =
110 ->
T110 -
Smin=0'6mm-8'4mm
10 min -Smin 0 's7shm-8'4mm Two: 1min and T1o 10 '7min
=
(nc 40.21"
8T,V c 40.21 =) -solve the
↳
=
-+
c
=
1
0.Tn = C
UzTc c =
+ 118-187" =
C system =
=
3050
substitute for given U -

simplified Taylor: VT =
"=
Then U.T =
c -
> JS. Tos 3050 + Tos= 15'2 min
1 v =
80 + TooMI-O'EMM-8'ssmeT1 =
12m an
T801 Smin 0'7mm -8'28mm

v 80 T 15'Smin
-
2 +
=
+
omin-smin=8'40mm-o'comm
=
T100 smir 0'7Mm 8'49mm

Ts = 0 MM
- -
3 v =
100 + ->
100min-smin=0'04mm-8'49mm
C C'm
xpanded Taylor
=>
UT =
fnap" **T= 0'fu*ap"
we chose cases with ste parameters between them to solve the exponents
2-3: fn =
ete and ap = ste
vTr
=
U3T3 = ap" =
Cte +"
- >
->
8 (5s1"
=
-
n 0337
=
1-2: 0 =
ste and ap =
Ce
&T,"ful "a" = QTc"fria"->I= I" 1o3sE I1" -> ->

1 0388
=
substitute
1. in any process to get the ste C
8 T, "fn," a/"=c ->

(= 88.120337.8'g0'388=141'LS
if a parameter is always so we consider it as part of (and take it out
141'IS
UT0'337 =
fnO'387
0 =178m/min T. =
0min oc=10M/min UBFO'Amm tc=16min
same cutting conditions fn

-> =
ste and up-ste
'n
↑ o, "n.f.Y.apyn= TzE ".fy.an -F 1) =
= Hols'
*
->
Tc =2129min
Admissible flank wear: trti vtrBr-7 5 = =

->
UB 0'743=
C'm
T 0'nfn*/aPY In
=
1 2: f =
C++ and ap =
se
158
f
I
ap
I
T
4 '36
FintWatan-Do EIME
188 I I 198 2-3: ap = CTe
208 I's 1 2368 xTiV 2Y 8sT3+3" = -

E (73)x =
228 1's 2 383 +
ju)0'19s (,1"
8(t = -
x 16256
=
3- 4: f =
Cte
1 (PY
Y
83T3"ap3" 0xT4"ap4"
=
= -
+
+80(53680C19(1"- y =0'439 E
Taking any process, for instance 1:

C
C
OTr =
f "ap"
-> 158.4380'7195 11656.104393
=
-( 187'13
=
ap:
20723%8'2195
T
=
v Youlas fn"6s610419s ap6393/01a)
=
5
turning.
=300 10 120
=
DF 90ks 750 m kv 7502a 12

= = =
=
rc 08=
f + [0 2,08]mm, rev vc 230Mn
=
n 1200r1m
=
a) strategy (min. number ofpasses, feed anddepth of cut).

apmax
sinkr=ea
->
apmax sin75.12:11'59mm
=
apmaxi, kry e (0 DF)(2 (120 98)/2 -

-
- a
no passes = =
1.29
=
2
-
cutting apmax 1159

edge angle
wealwaysroundup
aseries
thenumber
of
1| 2
Finishing:we takeapFINISH 1 mm
=
7's 2
oacapfinish
1
x
-
Therefore aproughing =
=
7mm
=
2 passes for roughing up- trm and pass for finishing ap =
trm
To determine the strategy:
1) compute their passes from apmax and round up-rpasses rough
2)From the n of passes compute the real ap

3)Add one finishing with apfinish
pass for = Trm
apn passes rouahing apfinish -
4) aprovah =
~ passes roughing
6Dimension of the undeformed Chip section (b xh)
- -; irsinkr=tnpcb
f
=
n g
A very small portion of material is not being removed, this causes surface
finish but it's NOT TAKEN INTO ACCOUNT
frouh = fmax ffinish: fruit
aprovah/sinko 7/ sinzs
Rooahing(b
= = =
='lsmm
n =
froth sinkr = 0.6.Sin7S=0'SOmm
(bh=ffinish. Sinkr=0'2.
apfinish/sinkr
= =
1/ sin7s =<.03mm
Finishing
Sin75=0'19mm
2) Area of undeformed section
Roudhing: Arovan 7x0'6=4'2mm:

sinter ( Finishing:
=
A = bon = of sinkr =
apof
Afinish 100'2 =
0.2mm2
=
6)components of the force

Fr +F+ Fc
= =
ksA
Ft Fc
=
ks.A
I
=
N Ithrust force
#+a dFr Fr =
N.COS Kr
t
- -
If =
Fa = N.Sin Kr
Fa*KrL
cutting force
-
#t Fc =
750.4'2=31SON
↳
=
Rorahing Fr =
0'7 FCCOSKr = 0'7-3150CO97S=S70'7N
F = Fa 0'7Fc =
sinkr=0'7.3150 Sin7S=2129'9N
790 "0'2=
Ft = 150N =
FC
Finishing I Fr
f
#
=
=
0'7.150COS7S= 17'18 N
0'7- 150 sin75= 1012 N
e) rotating speed: nCrpm]

Cutting speed: ocin) w(**) =
R(m) = TPF(mm8YCrpm
feed rate:of = +13nCrpm]
working at ste rotating speed:n =
12000DM
PASS DO Up DE UC fleM) of IMn)
I 128 7 108 488 O'8 728
2 106 7 92 347 8'6 728
3 92 I 98 339 O'2 248
*
Eon
I I 7 *
DF DO 1aD x Of = fU
= - =
working at the cutting speed: 0c=230min
PASS DO Up DE n fleM) of IMn)

I 128 7 108 69 O'8 414 '6
2 106 7 92 796 8'6 4775
3 92 I 98 813 O'2 182 '7

#
x =
on' n 5008
=
A PWRC =
Fc "Ocm -
cutting speed at the median point
working at ste rotating speed: + (120 + 106)/2-1100

DF)/2.n
mn π(D0
+
426 M/ min
=
1000 1000
= =
ocm =
PWRC = F(x0cm(1 3150 =
x
428 "50 =
22365W
PWRC*FCUC-approximation, we can perform this operation if
we indicate it's an approximation

PWRf=Fa of (51 =
2129'9.710 in 200
mm
mm in=cow
working at
stecuting,speios(12.691
rcm = my 1000 245m/ Min
=
-
↑WRL= FC10CM =
3130 "
249 "
60
=
12862's U
↑ WRf Fa < 0f =
2129'9.414's = 50 =
14'72W
Uremoved NIDOL DF? C TIDOL - -
DFP
9)MRR E Of
= -
4
=
t 4
working at ste rotation speed: MRR =

#
(1202-1864: 710
4 =1789200 M
#(1702 -1064 mms
working at she cutting speed:MRR 414'6=1030181
- . .
x
=
4 min
Another way: MRR =

πDmapf.n = πF F f.n =
1000.0cm.apf
h) Cotting power but taking into account MRR
PWRc =
ks MRR.
=
ks.10000cm.ap.f
nother way:PWRC =
Fc.rcm ks.f.ap.5cm
=
*
He rotation speed:PWRC= 750-1709200
He cutting speed: PWRC =

750"1030281
L #DF L
is cutting time to = o =
Fn =
1.10000
#DF
=
1000Ulf
->
+CT =
tCl
#106-300
PaSS1: tCl 0'42
I
= =
· 1000-400.8'6
n = cte =
1200rpm to
pass 2: t(z =
8'42 tCT = 2'09
*
PaSS 3: t(s =
1'lS
PaS91: tx1 =
0'72
0.63)
·
x ct
=
230m/min
=
-
Pasz: + x =
+ ( 319
=
*
PaSS 3: t(S =
1'84
j) PASS OC f AB T tcxn workpieces ↓tOOlS
I 238 8'6 7 12'89 0'71.80 = 57'91 4'49
2 230 8'8 7 12.89 50 '78 39
3 238 8'2 ↓ -> 984'71 147'SL 0'02

& *
4)119+ 3'9+0'02 = 8'41 ->9 tools
nitools-texnworkpieces
T
-round up
PASS OC f AB T texnworkpieces vitools
I 400 8'6 7 1'88 33'33 17 "87
2 347 8'8 7 308 33'33 10'89
3 339 8'2 ↓ 162'09 700 0'82
'87
17 +10'89 0'62=29'38
+ -
30 tools
k) +T = [+ 8piece+) It passi++repositioni)) ++ yonloaclingaxnworkpieces + hanging + in tool
Take into account that: touting machining = s

quees es?
e) Total height of the roughness profile
Rouahing-at = d =
0'60.08 =
0105615=s0'Sum
Finishing ->Rt= 0'2' 0.08 =
0100615=6'Mm
↑
Tool radius ->
↓ profile (better surface finish)
aFt =
c "ap"x +*xr," ->
Ft =
161'4apOU72.f0'S1. 8,0'87
1- 2: ap =
ete and 0c =Cte
=
#
-
=10 -
+0 18319
= -
0 = 0'S12
AFFCtvand ECe-o-(Ev
7- 4:
--v 0070
=
1 3:f=Cte and 0c =
cte
ix 3o-
#
=
=lP-o (53) -xx =
=
0'822
1.c =
F+/(ap-ff 0(V) = 40'4/18'500K 810311880070) 161'4 =
the same
Fr=47'rap0071.folUs. EC 0196
-
Repeating process
↑
If =
30'8ap0900. f004. Oc 8'747
bFt =
161'4. 10'812. 8'180312. 2250'07 =
136'UN
r
#
=
47'0.1's 0'071.0180'0S. 2250196 =1836 N
&
F3O'U'S81a86OIfOOL. ESO'CUE-63Yonthe
d) MRR = πD apf.n =
1000.00.apf=1000.225.1's.8'18 = 607s0 M
kr=750 Do =
100mmks=1700 m2 += 0M ap = 2'SmM
a) Ft F1 =
ks A kshb ksapf= 1700. 2's.0'1=13SON
I
= =
=
r 0'7FCCOSKV 0'7.1350 COS7S=14SN

# =
=
#f =
0'7.1350 SIU7S = 913N
b) PWRC = Fcx0cm 1350 x

=
13169:50 =
S21500N = Nocoincide el
(100 + 99)/2.COO
#
xcm =
1000 =
231'69 result aclo
F = Do-2ap=100-2.2's
↓ = 95
PWRf =
Fax 0f =
913x100 "50 "000=1'32W
of = f.n 0'2=
x
S00 =
100
150mm
↓= DF 0 SMM f= 0'13mm, rev
3
=
PWRf=PWRMaX
xc = 90m/min
PWR =
1000 1=S0% E=17385/M3
a) MRR = 11978MMS/min Nolose wif me faltan datos: ')
b) PWRc =
ks MRR
·
=
ks.10000 m. ap.f-
MRR 1000. Ocapf
= +
21970 =
90-1000 ap.0'13->ap = 1'U7
1o DF=
+
29p =
6S +
21'U7=68'74mm
1) IT =
Ifloading position +
tmachining) parts
c5OFS
tCIOCHLOLOEs9ELIMA
->
MESOcOE ITI
No =
30mm DF =
25mm ( =
200mm kr = 750 += 0'Imm/ver
xc=300m/ Min kS=3000N/MM2
937'5.2003
af = 4 3.21.183.3976070
=
= 0'299
Imax = to"- 130"=39768'7Ummy

E 211.10SN/MM2
=
L= 200mm
07SF Fc
=
-
F 17Fc
=
= 1'79-798: 937'N
#c Ft ksA ksbh ksapf= 3000.2's.011: ISON
=
= = =
ADF 10
-
1
ap =
=
=
1'smm
b) what has the keto do with this? Is it smthg like: as knsgo we
need to take a different component of the force?

Either way, I tried computing the other 2 components of the force and
still couldn't get to the result
xe=250M/ min=cte += 02mm/ver ap=14mm T = 2'29
+changing 0'min
=
For8744 +250 THYU 1069'59-0f1 n1f 21392

a
o
=
n1
-
- = = =
-
= ·
For 000U onc =
1156'63rDm ->
Ofz =
1156'65.0'2=231'33
↑
For 860'4 -
43 = 1317 's/UDM-> Of 3 =
1317'51.0'2 =
163's8
H
+repOcitontrs
L3
tworkpieceOWIItrePOSitiOUlt =
c'a min
Y
Data missing?
A stat, there's no need to add the tool-changing time
b)t1o = 20: tworkpiece = 10.1.9=38
notools-ty+= 30/2'19= 16'59-round up 17 tools
d+T +20 +htools (loading

=
+
tunloading) changing tool
+
tools
38+ 1010'2
=
+
0'11 +
17x0'6= 542min
DO SOMm
=
NF =
20mm 1=180mm PWR 0.85 +9000W
=
039
ks 1980. 1
-
a) 3 steps ap Cte
=
facte 0c=289m/ min kr=790
f f [8'2,0S]
ap 1450F)(2 1510,c
=
=
=
smm
tC 0c x1
=
->
tcmin ocmin
=
xL
S
sho
ks/M"orO-Issn
PWR FC.W-0 0.85 .9000
=
=
o
solving the equation:n 0'12

=
f H/Sin7S 0 12/S147S
=
= 02 =
180
b) machining o= =
195'70 09195 =
of 1.f
=
1631340'12 195'76
=
=
1000
285,000
UC
183134 UpM
=
=
n Di
=
tworkplace 3 passes machining 3.0'9195: 1'758

= =
x+
no tworkpiece
workpieces tool = 9'13, 2'758 3.31
=
-4 workpieces
43. 107
T
10S3'48(222s12 9'13
=
=
Do =
127mm ( =
300mm f = 0'22hm /rer 9p= imm
approach distance owm
=
If 0c=100M/min-H001/sworkpieces -
T= S
If 0c =120M/ min-1001/24 workpieces ->

T= 14
rs? For Itool/30 workpieces

T10x =
T10K-b = -
(t) t0 = ->
x 0288
=
O'2S8
T 3UC3 = Cte = T1Ul -
>30 Uc3 = 90150. 180 -> Uc3=11337m/min
n OOTN
=
1.3 '37.1000
H. 129
=
288'69rDM
DF D0-29p
=
= 127-2x =
115mm
tmachining = nworkpieces: F =
30: 1
500 =
1417 min
Of = n. f = 288'69.0'22= 63's1
xo= 32mm DF 30mm=
1=s0mm a provan = Ctr
apfinish - Imm Pwk=0'US "

17000 n 4000rpm
=
kr = 930 ea = 4mm xc=390m/min ea 4mm-

=
55
frovah =
0'ss mm / rev
+finish = 0'3 Ks=750N/mm=
Roughing: this is the max aprovgh
PWR =
FC. Uc= Ksaproah frovah. O we can achieve, not the
O'us. 11000 =
750.aprouah +0'SS=590 aprouah
->
= 3'49x real
↓
Froudh = DF +
2apfinich =
30+2x1=32MM one yet
↓
Frough = D0 -2xaprough "
n passes ->
32=S2-2.3'49.npass
nroughing passes -
2'07-3roughing passes
o-DFrOUCH
*
Asaprovah=cte ->
rpasses)/2
aprouh =
C
aprovan= (5534/2=3133mm
333.1)1
Eh π.151 1000
-
x
= -
+
398
=
->
wouah= 27386 rBW
Ofrovah= Mouah-frovah 27386

=
x0'S5=1506'2mm/min
trovan-Erran" npack =
3 = 0099smin
remember to check the max
condition always
Finishing: DIU
-
Foto
#
Uc =
1000 390 =
finich 4138>nfinish max 1,000
- =
# 304000
uc =
1000 = 377
offinish = Ufinish affinish 4,000 x

=
0'3=1200mm, min
+finish: nish= 580 =
0'042
tT trough +ffinish 0'0999+0'042=0'1412 min

=
Rohing: 3 passes ap 333 += 0'SS 01 398

=
=
Finishing: I pass up 1
=
+ 0'3
=
0C =
377
when they ask for strategy, give no passes, ap.f, rc and machining
for both roughing and finishing stages
Do=s3mm DF = 63mm 1= romm oc=230m/min T= Ismin
disto=4mm vchip=14100mm3 niorkpieces/tool? time?

MRR = (hip =
ap.5c.tn -o 00 = $83230
in
183mm
im fn-fn = 0'485M
n 5000 238.1000 1162'08 UPM
=
+Machining-TiSebof HolM=OOSomereal
=
=
some
-
min
15
"parts,tool-tmachining =
0 1090 =
0844 -
Rood -
down always
*
No coincide el resultado
Let's assume that treposition -

position = distor of ="/471'01
toT =
n parts streposition+ + machinina) = 801N1 "U1) =
15'67 min
Do =
50mm DF =
20MM PWR: 8KW 1
=
03%.
3 passes -> se up, etc++100s.0127, and ste 01-105 m, min
Ks = 157'0/f039 (daN/mm 2]
alf for minimum machining
machining = -> for machining min--max
look for the max feed satisfying the specifications

PWR ks.fu.ap.0
=
-> 0.183.8'us = 5aN,NN.f.s.zosin in

Do -DF
reduction per pass =
n passes = 50510 =
18
perpass
ap = reduction -
=S
solving the equation: f= 0'losmm -> 1000s, 8'2
bux = in
180 ->
T1 = 30min and ox= n -T2
225 = 10 min
188.38Ctel e
S /tel=Ol
=
C+e2
Oci x TiCTen = Cte2
solving
->
(tel
225. 18 =
Cte2
for Uc=10S- T0103

103. =
399-T = 15'Umin
↓
o= 125mm DF 120mm
=
f= 0'smm, rev n =
6000DM
If 19min
I
n =
S300DM ->
T1 =
335
If ne =
000rDm ->
Tc = 17min 40S
↓ inserts for 100 workpieces

F 20 199.81 m, min
"0F/
=
=
-x
=
x =
UCL APF VOOT

-
1000
2O
= =
38159m/min
sdEl.IYETBEsooMcGiNEITEEFElr=
C+ 1 0'8
OciTic'
h (
=
= c+2 -
C+ 2 =
3000
TO solve this wct1?

or-...-
#
Df1 = Dmean= 2 =
122's mM
xc nTbf =
=
600T.127's
1000 =
238'91 m/min
00.T100 3,000 = -
230191. T,00 =
3,000 T1
-
=
24.67min
tmachining
= fn =
99'23
01,600 =
1170 min
4 = 100 COSX= 100. 1017'13=99'13*be not turning, conical

1139-110)/2
x arctg
=
100 =
F'13
FOr-....-D+z 139 =
600T13S
uc =
1000 =
294147m/min
254'47.T20'0 =
3000 ->
Tc 21'US
=
+machining
:
n =0is 3000 =
1'

ninserts - parts - machining -100:7=a's-bound-up
to
10 Inserts are needed
L = 300mm Do= 125mm += 0'225mm/rer ap =

2mm
disto =
6MM 3 workpieces load =
140S t?
I
If un=180m/min-o
Tool/sworkpieces,Instead of having Tin (min
If ux=120 M/min-Hool/2s workpieces we can have it in (workpieces]
T1C +188.gCt =c+2

z/(x1.T2
c+2 C+ 1 0'252
+ic
=
c+2-solving4c
=
Oci. c+
=
=
xx. 2+2 -120.25( = +2 = 170
From the tool life equation we have obtained, get oc:
0.TO'52=170 -> Uc.380151= 170 -

0c=114's9m, min
n TDF
=
xc.1000
=
11419.1000
121 =
381'4SUBM
DF =
DO-19D= 12S-2.2=121
388
IMACUMMING ASE3OYS.ORLS-CIm
this
t =
nworkpieces "
(machining +floading ++ approaching) =
=
emin(
3014'42+0'080+1403509 =
20S'11 min
No =
300mm 1=1000mm f=04mmirer ap: 31m
148M/min ->T= 96min 148.9gCt1=C+2
I
+ 4
S
rc C 0'23
c+c(c
= =
x =
102 m/min-T =
19'smin 282.19'sct1 =
+2 =
400
If Ito01/workpiece -
T: machining
1000
tmachining = = 0'4(0(100011.494) = T
Uc.1000 Uc.1000
=
n HDF π. 494
=
↓
F =
Do-19D =
S00-2.3:494
xc.4043 =
4100 -orc (0x000001023 =
100 -
pvc =
202'92in
No = 210mm 1 = 300mm DF =
90mm PWR=11.183W 4 = 0'
nmax =
500rpm ea Mm
=
ks=1700N/mmz Orepos =
10.9
*
max effective cut length =
apmax I
TOO1 1: x = 900 treposit=tmachin/18
t = YIfin) ->
for twin ->
hmax -
n nmax
=
=
S0OPDM
DFU
#
#706.SOO
x 1000
=
1000 323'58m, min
=
*F D0 -19D
=
= 218-1.6=106
PWR = FC. Uc(m(c) + Fc.COSX. MRR.n too o

usually tool is at 90 - COSx =
10190 =
0 ->
PWR: FC.UCSM/s]
11000.0' = Fc.373'388 -oFc=1631'74

Fc ks
=
.apf ->
1631'74= 1700.6.f->f=0'Tmm/ver
IDO -
DF)/2 (218 98)/2 -
npasses 18'67-11 passel Round Up

508.10
CD
= - =
+machining at = =
+position = tmachining, 10 = 0/10 =
0'6
t = n passes (machining +
treposit) = 1716 +0'81=72'6min
we'd have to repeat the same for x = 13 and chose the option with
smallest to

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2º Grado en Ingeniería Mecánica

Escuela Politécnica de Ingeniería de Gijón

Reservados todos los derechos.

2) The iso code system could be applied to:

↑ he axis of the small cylinder

the upper limit deviation is 8

6) which type of geometrical tolerance should be applied to two cylindrical

inclined so with regard to the datum A.

A theoretical exact dimension

shall not be associated with tolerances

a) which of the following annotations implies larger diameters in a cylindrical surface?

Holes and shafts involved in a fit

tolerance grade means.

A larger tolerance interval

of the figure is the space between 2 planes

is medium between Lambda -

top surface should be contained between two parallel

planes 02mm apart ?

The one on the left

161 General tolerances

171 If the tolerance tones of the two parallel tolerances are

tolerance tone to be contained between two planes parallel to A and perp to B. .

The one whose value is 012

191 For the same nominal site which sentence is true ?

ITG implies better precision that 11-7

An internal feature of site ,

The fundamental deviation

251 which geometrical tolerance is only applied for controlling axes ?

The one on the left

261 what is the mistake in " 0010s A

is contained within the other , then the type of fit is :

281 Which of the following designations corresponds to a shaft basis system ?

machining processes lmecanitadol

31 ) The type of fit 80558 / is 7 is :

surface to be contained between two parallel planes separated 00s apart ?

337 The application of a selective fit system involves

341 In which figure the geometric tolerance is controller the

lower planar surface of the step ?

In the 0hL Of the left

35) If the axis of the hole I first row first column ) of

actual part was located at from A

and at 12 from B Dart should be

381 A geometric tolerance of location also restricts

Both the form and orientation of the tolerance feature

Arithmetic mean deviation of the roughness profile

The one on the right

451 ☐atoms are needles for controlling

461 Which geometrical tolerance dos NOT control the location ? n

The one on the middle

471 In a dimensional tolerance the fundamental deviation is the one related to . . .

The limit that is closer to the nominal site .

48 ) which type of fit does correspond to 4013766 ?

so) what does the indication im DIY ?

3) In which process is mandatory to apply a force in the same direction as that of

the movement of the final section ?

material can cause

Both : non enclosure of dies / die breakage .

7) In rotary draw bending of tube ,

To avoid that the tube buckles or folds

The one on the left .

9) what defect presents the sheet metal rolled in the figure ?

which tool performs the function of the die ?