Industrial Engineering Program Assignment 4

IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

Summary

Rolling Process
draft: 𝒅 = 𝒕𝟎 − 𝒕𝒇

Max. draft: 𝒅𝒎𝒂𝒙 = 𝝁𝟐 𝑹

𝒕
True strain: 𝝐 = 𝒍𝒏 ( 𝟎 )
𝒕𝒇

𝑲∈𝒏
̅̅̅𝒇 =
Average stresses experienced by the work in rolling: 𝒀
𝟏+𝒏

̅𝒇 ∗ 𝒘 ∗ 𝑳
Rolling Force: 𝑭 = 𝒀

Roll-work contact area: 𝑳 = √𝑹(𝒕𝟎 − 𝒕𝒇 )

Rolling Torque: 𝑻 = 𝟎. 𝟓 ∗ 𝑭 ∗ 𝑳

The power for each roll∶ 𝑷 = 𝟐 𝝅 ∗ 𝑵 ∗ 𝑻

Total power for both rolls∶ 𝑷 = 𝟐 𝝅 ∗ 𝑵 ∗ 𝑭 ∗ 𝑳

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

Forging Operation
Case I
Under ideal conditions of no friction between work and die surfaces

𝒉
True strain: 𝝐 = 𝒍𝒏 ( 𝟎 )
𝒉

The required Force: 𝑭 = 𝒀𝒇 ∗ 𝑨

Case II
Under Actual conditions of friction between work and die surfaces will
be considered

The required Force: 𝑭 = 𝑲𝒇 ∗ 𝒀𝒇 ∗ 𝑨

𝟎.𝟒 ∗ 𝝁 ∗ 𝑫
Forging shaping factor 𝑲𝒇 = 𝟏 + ( )
𝒉

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

Extrusion Process
𝑨𝒐
Reduction ratio: 𝒓𝒙 =
𝑨𝒇
Case I
Under the assumption of ideal conditions of no friction and no redundant
work
𝑨𝒐
True strain: 𝝐 = 𝒍𝒏 𝒓𝒙 = 𝒍𝒏
𝑨𝒇

̅ 𝒇 ∗ 𝒍𝒏 𝒓𝒙
The pressure applied to the ram: 𝑷 = 𝒀
Case II
If the friction is considered

True strain: 𝝐𝒙 = a + b * 𝒍𝒏 𝒓𝒙

a = 0.8, and b = 1.2 to 1.5

̅ 𝒇 ∗ 𝝐𝒙
The ram pressure to perform indirect extrusion: 𝒑 = 𝒀
𝟐𝑳
̅ 𝒇 ∗ ( 𝝐𝒙 +
The ram pressure to perform direct extrusion: 𝒑 = 𝒀 )
𝑫𝒐

The Ram Force: 𝑭 = 𝒑 ∗ 𝑨𝒐

The required power: 𝑷 = 𝑭 ∗ 𝒗

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

Wire / Bar Drawing Process

Case I
Under the assumption of ideal conditions of no friction and no redundant
work
𝑨𝒐 𝟏
True strain: 𝝐 = 𝒍𝒏 = 𝒍𝒏
𝑨𝒇 𝟏−𝒓

The stress that results from the ideal deformation pressure applied to the ram:
𝑨𝒐
̅𝒇 ∗ 𝝐 = 𝒀
𝝈=𝒀 ̅ 𝒇 ∗ 𝒍𝒏
𝑨𝒇
Case II
If the friction is considered
𝝁 𝑨𝒐
̅ 𝒇 ∗ (𝟏 +
The actual stress: 𝝈𝒅 = 𝒀 ) ∗ 𝝋 ∗ 𝒍𝒏
𝒕𝒂𝒏 𝜶 𝑨𝒇

𝑫
𝝋 = 𝟎. 𝟖𝟖 ± 𝟎. 𝟏𝟐 ∗
𝑳𝒄

𝑫𝒐 + 𝑫𝒇
𝑫=
𝟐

𝑫𝒐 − 𝑫𝒇
𝑳𝒄 =
𝟐 ∗ 𝒔𝒊𝒏 𝜶

𝝁 𝑨𝒐
̅ 𝒇 ∗ (𝟏 +
The Drawing Force: 𝑭 = 𝑨𝒇 ∗ 𝝈𝒅 = 𝑨𝒇 ∗ 𝒀 ) ∗ 𝝋 ∗ 𝒍𝒏
𝒕𝒂𝒏 𝜶 𝑨𝒇

The Ram Force: 𝑭 = 𝒑 ∗ 𝑨𝒐

The required power: 𝑷 = 𝑭 ∗ 𝒗

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

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 49.0 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.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

2. A 2.0-in-thick slab is 10.0 in wide and 12.0 ft long. Thickness is to be

reduced in three steps in a hot rolling operation. Each step will reduce the
slab to 75% 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 ft/min, and roll speed is the same for the three
steps, determine: (a) length and (b) exit velocity of the slab after the final
reduction. Note (1 ft. = 12 in.)

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

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? suppose that the percent reduction was specified to be equal for each
pass, rather than the draft. (c) What is the minimum number of passes
required? (d) What is the draft for each pass?

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

4. A continuous hot rolling mill has two stands. Thickness of the starting
plate = 25 mm and width = 300 mm. Final thickness is to be 13 mm. Roll
radius at each stand = 250 mm. Rotational speed at the first stand = 20
rev/min. Equal drafts of 6 mm are to be taken at each stand. The plate is
wide enough relative to its thickness that no increase in width occurs.
Under the assumption that the forward slip is equal at each stand,
determine (a) speed vr at each stand, and (b) forward slip s. (c) Also,
determine the exiting speeds at each rolling stand, if the entering speed at
the first stand = 26 m/min.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

5. A plate 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, (d) calculate the torque , and power required to
accomplish this operation if used a roll radius = 250 mm, (e) calculate the
torque , and power required to accomplish this operation if a cluster mill
with working rolls of radius = 50 mm. Compare the results with the results
obtained in (c) and (d), as well as note the discuss effect of roll radius on
force, torque, and power.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

6. A 4.50-in-thick slab that is 9 in wide and 24 in long is to be reduced in a

single pass in a two-high rolling mill to a thickness of 3.87 in. The roll
rotates at a speed of 5.50 rev/min and has a radius of 17.0 in. The work
material has a strength coefficient = 30,000 lb/in2 and a strain hardening
exponent = 0.15. Determine (a) roll force, (b) roll torque, and (c) power
required to accomplish this operation.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

7. A single pass rolling operation reduces a 20 mm thick plate to 18 mm. The

starting plate is 200 mm wide. Roll radius = 250 mm and rotational speed
= 12 rev/min. The work material has a strength coefficient = 600 MPa and
a strength coefficient = 0.22. Determine (a) roll force, (b) roll torque, and
(c) power required for this operation.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

8. A hot rolling mill has rolls of diameter = 24 in. It can exert a maximum
force = 400,000 lb. The mill has a maximum horsepower = 100 hp. It is
desired to reduce a 1.5 in thick plate by the maximum possible draft in one
pass. The starting plate is 10 in wide. In the heated condition, the work
material has a strength coefficient = 20,000 lb/in2 and a strain hardening
exponent = zero. Determine (a) maximum possible draft, (b) associated
true strain, and (c) maximum speed of the rolls for the operation. (d)
Calculate required (a), (b), and (c) again if the operation is warm rolling
and the strain-hardening exponent is 0.18. Assume the strength coefficient
remains at 20,000 lb/in2.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

9. 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 yield
strength of the work material is 285 MPa, and its flow curve is 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, (c) at a height of 30 mm,
and (d) at a height of 25 mm.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

10. A cylindrical work part with D = 2.5 in and h = 2.5 in is upset forged in an
open die to a height = 1.5 in. Coefficient of friction at the die-work
interface = 0.10. The work material has a flow curve defined by: K =
40,000 lb/in2 and n = 0.15. Yield strength = 15,750 lb/in2. Determine the
instantaneous force in the operation (a) just as the yield point is reached
(yield at strain = 0.002), (b) at height h = 2.3 in, (c) h = 2.1 in, (d) h = 1.9
in, (e) h = 1.7 in, and (f) h = 1.5 in.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

11. 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 5.00 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 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.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

12. A hot upset forging operation is performed in an open die. The initial size
of the work part 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.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

14. A connecting rod is designed to be hot forged in an impression die. The

projected area of the part is 6,500 mm2. The design of the die will cause
flash to form during forging, so that the area, including flash, will be 9,000
mm2. The part geometry is complex. As heated the work material yields at
75 MPa and has no tendency to strain harden. Determine the maximum
force required to perform the operation.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

15. 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.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

16. A 3.0-in-long cylindrical billet whose diameter = 1.5 in is reduced by

indirect extrusion to a diameter = 0.375 in. Die angle = 90°. In the Johnson
equation, a = 0.8 and b = 1.5. In the flow curve for the work metal, K =
75,000 lb/in2 and n = 0.25. Determine (a) extrusion ratio, (b) true strain
(homogeneous deformation), (c) extrusion strain, (d) ram pressure, (e) ram
force, and (f) power if the ram speed = 20 in/min.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

17. A 2.0-in-long billet with diameter = 1.25 in is direct extruded to a diameter

of 0.50 in. The extrusion die angle = 90°. For the work metal, K = 45,000
lb/in2, and n = 0.20. In the Johnson extrusion strain equation, a = 0.8 and b
= 1.5. Determine (a) extrusion ratio, (b) true strain (homogeneous
deformation), (c) extrusion strain, and (d) ram pressure at L = 2.0.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

18. An indirect extrusion process starts with an aluminum billet with diameter
= 2.0 in and length = 3.0 in. The final cross section after extrusion is a
square with 1.0 in on a side. The die angle = 90°. The operation is
performed cold and the strength coefficient of the metal K = 26,000 lb/in2
and strain hardening exponent n = 0.20. In the Johnson extrusion strain
equation, a = 0.8 and b = 1.2. (a) Compute the extrusion ratio, true strain,
and extrusion strain. (b) What is the shape factor of the product? (b)
Determine the ram pressure in the process.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

19. An L-shaped structural section is directly extruded from an aluminum

billet in which Lo = 500 mm and Do = 100 mm. Die angle = 90°. If the
flow curve parameters for the aluminum alloy are K = 240 MPa and n =
0.16, and the corresponding Johnson strain equation has constants a = 0.8
and b = 1.5, Determine (a) extrusion ratio, and the (b) shape factor, (c)
compute the maximum force required to drive the ram forward at the start
of extrusion.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

20. A cup-shaped part is backward extruded from an aluminum slug that is 50

mm in diameter. The final dimensions of the cup are OD = 50 mm, ID =
40 mm, height = 100 mm, and thickness of base = 5 mm. Determine (a)
extrusion ratio, (b) shape factor, and (c) height of starting slug required to
achieve the final dimensions. (d) If the metal has flow curve parameters K
= 400 MPa and n = 0.25, and the constants in the Johnson extrusion strain
equation are: a = 0.8 and b = 1.5, determine the extrusion force.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

21. A direct extrusion operation produces the cross section shown in Figure
P19.32(a) from a brass billet whose diameter = 125 mm and length = 350
mm. The flow curve parameters of the brass are K = 700 MPa and n = 0.35.
In the Johnson strain equation, a = 0.7 and b = 1.4. Determine (a) the
extrusion ratio, (b) the shape factor, (c) the force required to drive the ram
forward during extrusion at the point in the process when the billet length
remaining in the container = 300 mm, and (d) the length of the extruded
section at the end of the operation if the volume of the butt left in the
container is 600,000 mm3.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

22. In a direct extrusion operation, the cross section shown in Figure

P19.32(b) is produced from a copper billet whose diameter = 100 mm and
length = 500 mm. In the flow curve for copper, the strength coefficient =
300 MPa and strain hardening exponent = 0.50. In the Johnson strain
equation, a = 0.8 and b = 1.5. Determine (a) the extrusion ratio, (b) the
shape factor, (c) the force required to drive the ram forward during
extrusion at the point in the process when the billet length remaining in the
container = 450 mm, and (d) the length of the extruded section at the end
of the operation if the volume of the butt left in the container is 350,000
mm3.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

23. A direct extrusion operation produces the cross section from an aluminum
billet whose diameter = 150 mm and length = 500 mm. The flow curve
parameters for the aluminum are K = 240 MPa and n = 0.16. In the Johnson
strain equation, a = 0.8 and b = 1.2. Determine (a) the extrusion ratio, (b)
the shape factor, (c) the force required to drive the ram forward during
extrusion at the point in the process when the billet length remaining in the
container = 400 mm, and (d) the length of the extruded section at the end
of the operation if the volume of the butt left in the container is 600,000
mm3.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

24. A direct extrusion operation produces the cross section shown in Figure
P19.32(d) from an aluminum billet whose diameter = 150 mm and length
= 900 mm. The flow curve parameters for the aluminum are K = 240 MPa
and n = 0.16. In the Johnson strain equation, a = 0.8 and b = 1.5. Determine
(a) the extrusion ratio, (b) the shape factor, (c) the force required to drive
the ram forward during extrusion at the point in the process when the billet
length remaining in the container = 850 mm, and (d) the length of the
extruded section at the end of the operation if the volume of the butt left in
the container is 600,000 mm3.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

25. 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 angel 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.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

26. Rod stock that has an initial diameter of 0.50 in is drawn through a draw
die with an entrance angle of 13°. The final diameter of the rod is = 0.375
in. The metal has a strength coefficient of 40,000 lb/in2 and a strain
hardening exponent of 0.20. Coefficient of friction at the work-die
interface = 0.1. Determine (a) area reduction, (b) draw force for the
operation, and (c) horsepower to perform the operation if the exit velocity
of the stock = 2 ft/sec.

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 Industrial Engineering Program Assignment 4
IE 2521: Manufacturing Processes I Instructor. Ali Abd El-Aty

27. 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.

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