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I'm working on a engineering case study and need an explanation to help me understand better.

The hot compression tests on stainless steel were carried out on a thermo-mechanical simulator in the strain rate of 1 s^{-1}, 0.1 s^{-1}, 0.01 s^{-1}, 0.001s^{-1} and the deformation temperature 1000 ^{o}C.

A 10,000 – ton (8.88 x10^{7} N) press is used to forge stainless steel cylindiral rods that are 0.15 m high having a X-sectional area equal to 0.10 m^{2}. Assume a flow stress of 600 MPa is maintained throughout the forging process under conditions where µ = 0.1 at room temperature.

- What load is required for forging process at the beginning?
- What could be the the largest flow stress this press can handle if this metal piece is pressed to 50% of its height?
- The same steel but with a
__square x-sectional__area is hot forged at 1000^{o}C to half of its original height by a platen velocity at 0.75 cm/s.**Use the above graph**to determine C and m values. Show your C and m calculations on excel. Excel spreadsheet will be submitted.**Graphite**is used as lubricant between the platen and the workpiece. Calculate forging force. Use the graphs, chart and table where necessary.

- The hot compression tests on an Aluminum alloy were carried out on a thermo-mechanical simulator in the strain rate of 0.01 s
^{-1}, 0.1 s^{-1}, 1.0 s^{-1}, 10 s^{-1}at various deformation temperatures. - The hot compression tests on an Aluminum alloy were carried out on a thermo-mechanical simulator in the strain rate of 0.01 s
^{-1}, 0.1 s^{-1}, 1.0 s^{-1}, 10 s^{-1}at various deformation temperatures.

A single pass cold rolling operation reduces a 20 mm thick plate to 17 mm. The starting plate is 200 mm wide Aluminum alloy. Roll radius = 300 mm and rotational speed = 12 rev/ min. The work material has a strength coefficient = 600 MPa and strain hardening exponent = 0.22. Coefficient of friction between the rolls and the work is assumed to be µ = 0.08. Determine:

(a) if the friction is sufficient to permit the rolling operation. If not, what should be the minimum friction coefficient for the operation to happen?

(b) if the deformation occurs without spreading (plane strain condition). If not what kind of precautions would you suggest?

(c) roll force, torque on one roll and total power required for this operation (in HP units),

(d) rolling force and power required for the same amount of deformation under hot forming conditions at 400^{o} C. For hot forming, mineral oil with µ= 0.2 is used as lubricant. **Use the above graphs** to determine C and m values. Show your C and m calculations on excel. Excel spreadsheet will be submitted. Explain the difference in power and force requirements between two forming operations.

Use the graphs, chart and table where necessary for your calculations.

__Formula Sheet:__

F = K_{f} .σ_{f}. A_{m}

K_{f} = 1 + (0.4 µ D/h)

σ_{f} (ave) = K ε^{n} / (1+n)

σ_{f} = K ε^{n}

d_{max }= µ^{2}. R

F = σ_{f} (ave). w. L. Q_{p}

L = √ R (t_{o} – t_{f})

T(one roll) = 0,5 F. L_{}

P = 2. π. N. F. L = ω T = (v_{r}/R).F.L

745.7 W = 1 HP

F = σ_{f} (ave). w. L

**έ**** = v/h**

**έ _{(ave) }= (v_{r}/L)ln(t_{o}/t_{f})**

v_{r} = 2πNR

σ_{f = } c**έ ^{m}**

σ_{f = } c**έ _{(ave)} ^{m}**

ε = ln (l/l_{o}) = ln (e+1)

e_{UTS} = exp(n) -1

σ_{t} = σ_{eng} (e+1)

σ_{t(UTS)} = UTS exp(n)

Multiplying factor for plane strain condition

The hot compression tests on stainless steel were carried out on a thermo-mechanical simulator in the strain rate of 1 s^{-1}, 0.1 s^{-1}, 0.01 s^{-1}, 0.001s^{-1} and the deformation temperature 1000 ^{o}C.

A 10,000 – ton (8.88 x10^{7} N) press is used to forge stainless steel cylindiral rods that are 0.15 m high having a X-sectional area equal to 0.10 m^{2}. Assume a flow stress of 600 MPa is maintained throughout the forging process under conditions where µ = 0.1 at room temperature.

- What load is required for forging process at the beginning?
- What could be the the largest flow stress this press can handle if this metal piece is pressed to 50% of its height?
- The same steel but with a
__square x-sectional__area is hot forged at 1000^{o}C to half of its original height by a platen velocity at 0.75 cm/s.**Use the above graph**to determine C and m values. Show your C and m calculations on excel. Excel spreadsheet will be submitted.**Graphite**is used as lubricant between the platen and the workpiece. Calculate forging force. Use the graphs, chart and table where necessary.

A single pass cold rolling operation reduces a 20 mm thick plate to 17 mm. The starting plate is 200 mm wide Aluminum alloy. Roll radius = 300 mm and rotational speed = 12 rev/ min. The work material has a strength coefficient = 600 MPa and strain hardening exponent = 0.22. Coefficient of friction between the rolls and the work is assumed to be µ = 0.08. Determine:

(a) if the friction is sufficient to permit the rolling operation. If not, what should be the minimum friction coefficient for the operation to happen?

(b) if the deformation occurs without spreading (plane strain condition). If not what kind of precautions would you suggest?

(c) roll force, torque on one roll and total power required for this operation (in HP units),

(d)rolling force and power required for the same amount of deformation under hot forming conditions at 400^{o} C. For hot forming, mineral oil with µ= 0.2 is used as lubricant. **Use the above graphs** to determine C and m values. Show your C and m calculations on excel. Excel spreadsheet will be submitted. Explain the difference in power and force requirements between two forming operations.

Use the graphs, chart and table where necessary for your calculations.

__Formula Sheet:__

F = K_{f} .σ_{f}. A_{m}

K_{f} = 1 + (0.4 µ D/h)

σ_{f} (ave) = K ε^{n} / (1+n)

σ_{f} = K ε^{n}

d_{max }= µ^{2}. R

F = σ_{f} (ave). w. L. Q_{p}

L = √ R (t_{o} – t_{f})

T(one roll) = 0,5 F. L_{}

P = 2. π. N. F. L = ω T = (v_{r}/R).F.L

745.7 W = 1 HP

F = σ_{f} (ave). w. L

**έ**** = v/h**

**έ _{(ave) }= (v_{r}/L)ln(t_{o}/t_{f})**

v_{r} = 2πNR

σ_{f = } c**έ ^{m}**

σ_{f = } c**έ _{(ave)} ^{m}**

ε = ln (l/l_{o}) = ln (e+1)

e_{UTS} = exp(n) -1

σ_{t} = σ_{eng} (e+1)

σ_{t(UTS)} = UTS exp(n)

Multiplying factor for plane strain condition

MFGE-205 Fall 2021
Name, Lastname: ________________________
Take-Home Final, Dec 28, 2021
ID#:
________________________
Honor Pledge: I hereby pledge my honor that I will work alone without any
outside help or material and I accept all the consequences if I act otherwise
Signature:
Problems
1.
The hot compression tests on stainless steel were carried out on
a thermo-mechanical simulator in the strain rate of 1 s -1, 0.1 s-1,
0.01 s-1, 0.001s-1 and the deformation temperature 1000 oC.
A 10,000 – ton (8.88 x107 N) press is used to forge stainless steel cylindiral rods
that are 0.15 m high having a X-sectional area equal to 0.10 m2. Assume a flow
stress of 600 MPa is maintained throughout the forging process under conditions
where µ = 0.1 at room temperature.
a. What load is required for forging process at the beginning?
b. What could be the the largest flow stress this press can handle if this
metal piece is pressed to 50% of its height?
c. The same steel but with a square x-sectional area is hot forged at
1000 oC to half of its original height by a platen velocity at 0.75 cm/s.
Use the above graph to determine C and m values. Show your C
and m calculations on excel. Excel spreadsheet will be submitted.
Graphite is used as lubricant between the platen and the workpiece.
Calculate forging force. Use the graphs, chart and table where
necessary.
2. The hot compression tests on an Aluminum alloy were
carried out on a thermo-mechanical simulator in the strain
rate of 0.01 s-1, 0.1 s-1, 1.0 s-1, 10 s-1 at various deformation
temperatures.
A single pass cold rolling operation reduces a 20 mm thick plate to 17 mm. The
starting plate is 200 mm wide Aluminum alloy. Roll radius = 300 mm and rotational
speed = 12 rev/ min. The work material has a strength coefficient = 600 MPa and
strain hardening exponent = 0.22. Coefficient of friction between the rolls and the
work is assumed to be µ = 0.08. Determine:
(a) if the friction is sufficient to permit the rolling operation. If not, what should be
the minimum friction coefficient for the operation to happen?
(b) if the deformation occurs without spreading (plane strain condition). If not what
kind of precautions would you suggest?
(c) roll force, torque on one roll and total power required for this operation (in HP
units),
(d) rolling force and power required for the same amount of deformation under hot
forming conditions at 400o C. For hot forming, mineral oil with µ= 0.2 is used as
lubricant. Use the above graphs to determine C and m values. Show your C and
m calculations on excel. Excel spreadsheet will be submitted. Explain the
difference in power and force requirements between two forming operations.
Use the graphs, chart and table where necessary for your calculations.
Formula Sheet:
F = Kf .σf. Am
Kf = 1 + (0.4 µ D/h)
σf (ave) = K εn / (1+n)
σf = K ε n
dmax = µ2. R
F = σf (ave). w. L. Qp
L = √ R (to – tf)
T(one roll) = 0,5 F. L
P = 2. π. N. F. L = ω T = (vr/R).F.L
745.7 W = 1 HP
F = σf (ave). w. L
έ = v/h
έ(ave) = (vr/L)ln(to/tf)
vr = 2πNR
σf = cέ m
σf = cέ(ave) m
ε = ln (l/lo) = ln (e+1)
eUTS = exp(n) -1
σt = σeng (e+1)
σt(UTS) = UTS exp(n)
Multiplying factor for plane strain condition
...

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