Department of Mechanical Engineering

MANIT Bhopal

ME 223 Manufacturing Processes 1

Assignment #5 Due Date: April 18th 2024, 5.00 PM

Problem 1: Mention some advantages and disadvantages of extrusion of aluminum alloys by

forward and backward extrusion processes. Suppose you are to put up an extrusion plant for
production aluminum rod, write down the main arguments for selection of each of these
extrusion methods for this purpose.

Problem 2: Determine the percent increase in yield strength of annealed aluminium bar, if it is
elongated from 200 mm to 250 mm. The yield strength of annealed aluminium at zero plastic
strain is 43 MPa and strain hardening exponent is 0.204.

Problem 3: How does the strain rate affect plastic forming process? A constant effective strain
rate of 10 per second is to be maintained in a plane strain compression test where the initial
specimen height is 10 mm. Determine the necessary velocities in the test as the height of the
specimen decreases.

Problem 4: Approximate recrystallization and melting temperatures of 8 metals/alloys are given

below:

S.No Materials Recrystallization Temperature Melting Temperature

(°C) (°C)
1. Copper (99.999%) 120 1084
2. Aluminum (99.999%) 80 660
3. Nickel (99.99%) 370 1453
4. Iron (electrolytic) 400 1538
5. Magnesium (99.99%) 65 650
6. Zinc 10 419.5
7. Tin −5 232
8. Lead −5 327.5

Find out a general range of ratio of recrystallization temperature to homologous temperature

from this data.
Hint: Let Tr = cTm, where Tr is the recrystallization temperature and Tm is the melting
temperature in K. Let the upper bound on c is cu and lower bound is cl. Solve the following linear
programming problem:

  cu  ci  Tm i
8
Minimize
i 1

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Subjected to
cu Tm i  Tr i ,

 i  1 to 8
c Tm i  Tr i , 
l

cu ,cl  0
Problem 5: A block of 30 mm height is getting compressed to reduce its height to 15 mm. If the
velocity of the movable platen is 2 m/s, plot the variation of the strain rate with respect to the
height of the block (from 30 mm to 15 mm). What are the minimum and maximum strain rates?
Ans:

2000 mm/s
Uniform load
30 mm

15 mm
Initial configuration Final configuration

Problem 6: A rolling mill experiences a roll force of 60 kN while rolling a strip of 40 mm width
and 3.2 mm thickness sheet to 20% reduction. If the roll of 200 mm diameter is made of alloy
steel, find out the radius of deformed arc of contact using Hitchcock’s formula.

Problem 7: In the rolling plant, the following relation is employed to estimate the coefficient of
friction for the evaluating the rolling process performance:
1 h1r
 min 
2 2R
where h1 is the inlet thickness, r is the fractional reduction (draft/inlet thickness) and R is the roll
radius. Support your answer by showing that rolling process is needed a minimum coefficient of
friction to start the production on the basis of theoretical analysis, and prove that the above
empirical formula is having practical application in the rolling plant.

Problem 8: Prove that the theoretical maximum possible reduction in wire drawing is about
63%.

Problem 9: In an extrusion process 99% reduction in the cross-sectional area is achieved. Find
out the corresponding extrusion ratio.

Problem 10: Prove that for a deep drawing process theoretical limiting drawing ratio is 2.718.

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