CHAPTER 15 15-1 Discuss the relative ease of hot-work and cold-work for the following metals: aluminum, Zirconium, lead, SAE 4340 steel, molybdenum. Consider the following factors: melting point, flow stress, oxidation behavior, brittleness. 15-2 When a compressive force of 400 tonnes (metric) is applied to the top surface of a well-lubricated cube it just causes plastic flow. The cube is 80 mm on each edge. What force would be required to produce flow if the faces of the cube other than the top face were constrained by die forces of 100 and 200 tonnes? 15-3 A circular plate is compressed by inclined dies, as shown below. The angle of the dies is small and sliding friction occurs at the surface with coefficient of friction yz, Derive the differential equation for normal pressure. What is the significance of the case when a = j? La 15-4 Calculate the ideal work of deformation per unit volume in drawing a wire through a die. Express in terms of the strain in the longitudinal direction. 15-5 The reduction per pass is given by q, = (hy-1 — fy) /hy 1, where n is the number of the pass Derive an expression between the total reduction Q, = (Jig ~ ht,)/ho and the summation of the reductions per pass q,. 15-6 Determine p/2k for a 50 percent plane-strain extrusion using the slip-line field given below. Frictionless. — 15-7 Determine p/2k for a 50 percent extrusion (frictionless) using the upper-bound field given below. Cae e 15-8 A frictionless uniaxial compression test of a copper cylinder gave the following results: ‘True stress, MPa | 28 | 69 | 110 | 165 | 221 | 262 | 276 | 285 | 290 Reduction in height, % | 0 Tasls Two ba 13 14 150 |(a) Plot the true-stress—true-strain curve in compression; (b) Construct an engineering tensile stress-strain curve up to the ultimate tensile stress from these data 15-9 Show how a value of flow stress independent of friction can be obtained with the compression test using an extrapolation method. 15-10 Derive the expressions for the flow stress and the strain in the plane-strain compression test 15-11 Compare the advantages and disadvantages of the tension test, the compression test, the plane-strain compression test, and the torsion test for determining the flow stress for metalworking processes. 15-12. In upsetting cylindrical specimens two types of cracks are observed: (a) vertical cracks which are parallel to the direction of compression and run into the specimen normal to its free surface, and (b) inclined cracks at approximately 45° to the direction of compression. Both types of fracture occur in the plane of maximum shear stress, which is a diametral plane at midheight. By applying Mobr's circle in three-dimensions show the two different stress states that must exist to produce these different fractures, CHAPTER 16 16-1 Plot a curve of p,,/a versus the parameter 2ua/h for a rectangular slab and a cylinder for values of the parameter from 0 to 5. 16-2 A 13 kN power forging hammer has a total nominal energy of 47 KJ. If the blow efficiency is 40 percent and the forging load builds up from P/3 at the beginning of the stoke to P at the end of the stroke, what is the total forging load for (@) astroke of 5 mm, (6) a stroke of 15 mm. 16-3 What would be the effect of the section thickness h on the forging load if the friction were reduced to zero? 16-4 Assuming that an average forging pressure of 340 MPa is required, what is the largest closed-die forging that could be made on a 350 MN press (the largest available)? 16-5 Show that the strains in the transverse and radial directions are equal for a thin circular disk compressed in the z direction. 16-6 Compare the average pressure needed to compress a cylinder 25 mm in thickness and 610 mm in diameter with one 3 mm in thickness and 610 mm in diameter. 16-7 An SAE 1040 steel at the forging temperature has a yield stress of 40 MPa. A right-circular cylinder 75 mm high and 25 mm in diameter is to be upset to half height between flat dies. (a) If the coefficient of friction is 0.4, what is the maximum force required for the upsetting? (b) How much extra force is required over what would be needed if no friction were present? (c) If it takes 3 s to produce the forging and the efficiency is 40 percent, how much power must be available in order to do the job?