Tarea 3 Procesos de Conformado Masivo

1. Indicate the mathematical equation for the flow curve.

Y f =K

2. How does increasing temperature affect the parameters in the flow curve equation?
The increasing temperature causes both the K and n in the flow curve to decrease.
3. Indicate some of the advantages of cold working relative to warm and hot working.
Better accuracy, better surface finish, increased strength due to word hardening, possible
directional properties due to grain flow, and no heating of work required.
4. Describe the effect of strain rate in metal forming.
The higher the rate of deformation of the work piece, the higher the strain rate. The specific
process and the physical action of the equipment being used has a lot to do with the strain rate.
The strain rate will affect the amount of flow stress. The effect that the strain rate has over the
flow stress is dependent upon the metal and the temperature at which the metal is formed.
5. Why is friction generally undesirable in metal forming operations?
Because it inhibits metal flow during deformation, causing residual stresses and product
defects. It also increases forces and power required and it increases waring of the tools.
6. What is sticking friction in metalworking?
Its when the work surface adheres to the surface of the tool rather than sliding against it. This
occurs when the friction stress is greater than the shear flow stress of the metal.
7. Advantages and characteristics of hot working relative to cold working.
Fracture of work part is less likely
Isotropic mechanical properties
Lower deformation forces is required
More significant shape changes are possible
8. Hot working of metals refers to which one of the temperature regions relative to the
melting point of the given metal on an absolute temperature scale?

0.6 T m
9. What is sticking in a hot rolling operation?
Its a condition in which the surface of the work piece adheres to the rolls as the piece passes
between the rolls, causing severe deformation of the metal below the surface in order to allow
passage through the roll gap.
10. Identify some of the ways in which force in flat rolling can be reduced.
Use hot rolling
Reduce draft in each pass
Use smaller diameter rools
11. Describe the different types of rolling mills.
Two high rolling mill: The metal passes in between two rolls once.

Two high reversing mill: The metal passes in between two rolls in one direction than in
the opposite direction.
Three high mill: three rolls are set to roll in the same direction and the metal passes
through them several times. An elevator is placed to lower or elevate the work piece so
it can roll in between the other rolls.
Four high mill: given that it is better to roll pieces with smaller radius but these can
deflect easily, rolls with bigger radiuses are placed to support the smaller rolls. The
piece is rolled in between the smaller rolls.
Cluster mill: a very thin roll is backed up by many larger rolls, it is a very rigid setup
and is used to make the thinnest pieces.
Tandem rolling mill: several rolling systems are placed in tandem and the material is
reduced as it passes through each set of rolls.

12. Why is flash desirable in impression-die forging?

It is desirable because its presence constrains the metal in the die to fill the details of the die
cavity.
13. What are the two basic types of forging equipment?
Hammers, which impacts the work part and presses, which apply a gradual pressure to the
work.
14. Name some products that are produced by extrusion.
Produced by continuous extrusion include structural shapes, tubes and pipes, and rods of
various cross sections. Products made by discrete extrusion include toothpaste tubes, aluminum
beverage cans, and battery cases.
15. Why is friction a factor in determining the ram force in direct extrusion but not a factor in
indirect extrusion?
Friction is a factor in direct extrusion because the work billet is squeezed against the walls of
the container so that friction resists the movement of the billet toward the die opening. In
indirect extrusion, the billet does not move relative to the container walls, and thus there is no
friction.
16. What conditions promote center-burst in extruded products?
17. Although the workpiece in a wire drawing operation is obviously subjected to tensile
stresses, how do compressive stresses also play a role in the process?
Compressive stresses are present in wire drawing because the starting metal is compressed as it
is forced through the approach of the die opening.
18. In a wire drawing operation, why must the drawing stress never exceed the yield strength
of the work metal?
It shouldnt because if the drawing stress exceeds the yield strength, the metal on the exit side
of the draw die will stretch rather than force metal to be pulled through the die opening.
19. A series of cold rolling operations are to be used to reduce the thickness of a plate from
50mm 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?
Maximum draft = 2 R = (0.15)2(350) = 7.875mm
Minimum number of passes = (to-tf)/dmax = (50-25)/7.875 = 3.17
4 passes
Draft per pass d = (50-25) / 4 = 6.25 mm
20. A continuous hot rolling mill has eight stands. The dimensions of the starting slab are:
thickness = 3.0 in, width = 15.0 in, and length = 10 ft. The final thickness is to be 0.3 in.
Roll diameter at each stand = 36 in, and rotational speed at stand number 1 = 30 rev/min.
It is observed that the speed of the slab entering stand 1 = 240 ft/min. Assume that no
widening of the slab occurs during the rolling sequence. Percent reduction in thickness is
to be equal at all stands, and it is assumed that the forward slip will be equal at each
stand. Determine (a) percentage reduction at each stand, (b) rotational speed of the rolls
at stands 2 through 8, and (c) forward slip. (d) What is the draft at stands 1 and 8? (e)
What is the length and exit speed of the final strip exiting stand 8?
21. A plate that is 250 mm wide and 25 mm thick is to be reduced in a single pass in a twohigh 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. Assume that the coefficient of friction is appropriate so that the rolling
operation is possible. Determine (a) roll force, (b) roll torque, and (c) power required to
accomplish this operation.
22. A hot upset forging operation is performed in an open die. The initial size of the workpart
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
diework interface = 0.40. Determine (a) final height of the part, and (b) maximum force
in the operation.
23. Determine the shape factor for each of the extrusion die orifice shapes in Figure P19.32.
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.
25. 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 workdie 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.