Model Answer

Metal forming 2021

QUESTION 1:
QUESTION 2:
𝜎𝑢𝑙𝑡 = 340 𝑀𝑃𝑎 𝑒 = 0.3

𝑛=𝜖

𝜖 = ln(1 + 𝑒) = 0.26
𝑛 = 0.26

𝜎 = 𝐾 𝜖𝑛

𝜎𝑢𝑙𝑡 = 340 = 𝐾 (0.26)0.26

𝐴𝑜 − 𝐴 𝐴 𝐴
𝑟= =1− =1−
𝐴𝑜 𝐴𝑜 exp(𝜖)

1 1
exp(𝜖) = 𝜖 = ln ( )
1−𝑟 1−𝑟

𝑟 = (𝑥 + 0.15)
300 = 482.6 𝜖 0.26

300
ln ( )
𝜖 = exp ( 482.6 ) = 0.161
0.26

1
ln ( ) = ϵ = 0.161
1−𝑟
1
= exp(0.161) = 1.175
1−𝑟
1 − 𝑟 = 0.85
𝑟 = 0.211 = 0.149 𝑥 = −1.3 × 10−3 ≈ 0

QUESTION 3:

cos 𝜃 − sin 𝜃 0
𝑅𝑧 (𝜃) = [ sin 𝜃 cos 𝜃 0]
0 0 1
1 1
− 0
cos 45° − sin 45° 0 √2 √2
𝑅𝑧 (45°) = [ sin 45° cos 45° 0] = 1 1
0 0 1 0
√2 √2
[0 0 1]

50 10 0
𝝈 = [10 20 40]
0 40 30
45 −15 28.284
′
𝝈 = 𝑅𝑧𝑇 (45°)𝝈𝑅𝑧 (45°) = [ −15 25 28.284]
28.284 28.284 30

𝜎𝑥 = −19 𝜏𝑥𝑦 = −4.7 𝜏𝑥𝑧 = 26.45

𝐼1 = 𝜎𝑥 + 𝜎𝑦 + 𝜎𝑧 = 100
2 2 2
𝐼2 = 𝜎𝑥 𝜎𝑦 + 𝜎𝑥 𝜎𝑧 + 𝜎𝑦 𝜎𝑧 − 𝜏𝑥𝑦 − 𝜏𝑥𝑧 − 𝜏𝑦𝑧 = 1400
2 2 2
𝐼3 = 𝜎𝑥 𝜎𝑦 𝜎𝑧 + 2 𝜏𝑥𝑦 𝜏𝑥𝑧 𝜏𝑧𝑦 − 𝜎𝑥 𝜏𝑦𝑧 − 𝜎𝑦 𝜏𝑥𝑧 − 𝜎𝑧 𝜏𝑥𝑦 = −53000

𝐼12
𝑅 = − 𝐼2 = 1933.3
3
 𝑅3
𝑇=√ = 16359.8
27

𝐼2 𝐼3 2𝐼13
𝑄= − 𝐼3 − = 25592.6
3 27

𝑅
𝑆 = √ = 25.386
3
−𝑄
𝛼 = arccos ( ) = 141.5 °
2𝑇
𝛼 𝐼1
𝜎𝑎 = 2𝑆 (cos ( )) + = 67.86 𝑀𝑃𝑎
3 3
𝛼 𝐼1
𝜎𝑏 = 2𝑆 (cos ( + 120°)) + = −16.17 𝑀𝑃𝑎
3 3
𝛼 𝐼1
𝜎𝑐 = 2𝑆 (cos ( + 240°)) + = 48.31 𝑀𝑃𝑎
3 3

𝜎1 = 67.86 𝑀𝑃𝑎, 𝜎2 = 48.31 𝑀𝑃𝑎 , 𝜎3 = −16.17 𝑀𝑃𝑎

𝜎𝑖

(𝜎𝑥 − 𝜎𝑖 ) 𝜏𝑥𝑦 𝜏𝑥𝑧

(𝜎𝑥 − 𝜎1 ) 𝜏𝑥𝑦
𝑎1 = | | = −2119.8
𝜏𝑦𝑥 (𝜎𝑦 − 𝜎1 )
(𝜎𝑥 − 𝜎2 ) 𝜏𝑥𝑦
𝑎2 = | | = 1081.8
𝜏𝑦𝑥 (𝜎𝑦 − 𝜎2 )
 (𝜎𝑥 − 𝜎3 ) 𝜏𝑥𝑦
𝑎3 = | | = −69.8
𝜏𝑦𝑥 (𝜎𝑦 − 𝜎3 )
𝜏𝑦𝑥 𝜏𝑦𝑧
𝑏1 = | | = −378.6
𝜏𝑧𝑥 (𝜎𝑧 − 𝜎1 )
𝜏𝑦𝑥 𝜏𝑦𝑧
𝑏2 = | | = −183.1
𝜏𝑧𝑥 (𝜎𝑧 − 𝜎2 )
𝜏𝑦𝑥 𝜏𝑦𝑧
𝑏3 = | | = 461.7
𝜏𝑧𝑥 (𝜎𝑧 − 𝜎3 )
(𝜎𝑦 − 𝜎1 ) 𝜏𝑦𝑧
𝑐1 = | | = −400
𝜏𝑧𝑦 (𝜎𝑧 − 𝜎1 )

(𝜎𝑦 − 𝜎2 ) 𝜏𝑦𝑧
𝑐2 = | | = −400
𝜏𝑧𝑦 (𝜎𝑧 − 𝜎2 )

(𝜎𝑦 − 𝜎2 ) 𝜏𝑦𝑧
𝑐3 = | | = −400
𝜏𝑧𝑦 (𝜎𝑧 − 𝜎3 )
1
𝑘1 = = 0.00169
√𝑎12 + 𝑏12 + 𝑐12

1
𝑘2 = = 0.00085
√𝑎22 + 𝑏22 + 𝑐22

1
𝑘3 = = 0.00162
√𝑎32 + 𝑏32 + 𝑐32

𝑙1 = 𝑘1 𝑎1 = −0.3592, 𝑚1 = 𝑘1 𝑏1 = −0.67779, 𝑛1 = 𝑘1 𝑐1 = −0.67779

𝑙2 = 𝑘2 𝑎2 = 0.92633, 𝑚2 = 𝑘2 𝑏2 = −0.15677, 𝑛2 = 𝑘2 𝑐2 = −0.34253

𝑙3 = 𝑘3 𝑎3 = −0.11348, 𝑚3 = 𝑘3 𝑏3 = 0.75090, 𝑛3 = 𝑘3 𝑐3 = −0.65068

QUESTION 4:
 𝑙𝑜 𝑑𝑙
𝜖̅ = ∫ = ln 1.25 = 0.223
0.8𝑙𝑜 𝑙

𝜎𝑡 = 𝐾(ln(1.25))𝑛

𝑑𝜖1 = 0

𝑑𝜖1 + 𝑑𝜖2 + 𝑑𝜖3 = 0

2
𝑑𝜖̅ = √ [(𝑑𝜖1 − 𝑑𝜖2 )2 + (𝑑𝜖2 − 𝑑𝜖3 )2 + (𝑑𝜖3 − 𝑑𝜖1 )2 ]
9

2 2×6 2
= √ [(𝑑𝜖3 )2 + (−𝑑𝜖3 − 𝑑𝜖3 )2 + (𝑑𝜖3 )2 ] = √ 𝑑𝜖32 = 𝑑𝜖3
9 9 √3
𝑙𝑜
2 𝑑𝑙 2
𝜖̅ = ∫ = ln 1.25
√3 0.8𝑙𝑜 𝑙 √3

𝑛
2
𝜎𝑡 = 𝐾 ( ln(1.25))
√3
 2 𝑛
( 3)
√

𝑛 = 0.5 ≈
25 %

QUESTION 5:
𝐻𝑜

𝐻1

Δ𝐻 = 𝐻𝑜 − 𝐻1 = 20 − 15 = 5 𝑚𝑚

𝑅 = 250 𝑚𝑚

𝛼 Δ𝐻 = 2 𝑅 (1 − cos 𝛼)

5 = 2 (250)(1 − cos 𝛼)

5
cos 𝑎 = 1 − ( )
500
𝑎 = 8.1𝑜

𝜇 = tan 𝑎 = tan 8.1 = 0.1425

𝐻𝑥

2𝜇𝐿
𝑛=
Δ𝐻

𝐿 = √𝑅Δ𝐻 = √25 × 5 = 11.18 𝑚𝑚

2 × 0.1425 × 11.18
𝑛= = 0.637
5
 𝐻𝑥 𝑛 𝐻𝑜 𝑛
(𝑛 + 1) ( ) − 1 = (𝑛 − 1) ( ) + 1
𝐻1 𝐻𝑥

𝐻𝑥 2 20 2
(0.637 + 1) ( ) − 1 = (0.637 − 1) ( ) + 1
15 𝐻𝑥
(𝑛 + 1)(𝐻𝑥𝑛 )2 − 2𝐻𝑥𝑛 𝐻1𝑛 − 𝐻1𝑛 (𝑛 − 1)𝐻𝑜𝑛 = 0

𝐻𝑥 = 5.262 𝑚𝑚

𝐵𝑆

𝑉 − 𝑉𝑜 𝑉𝑜 𝐻𝑥 5.262 7369
𝐵𝑆 = =1− =1− =1− = = 73.69 %
𝑉 𝑉 𝐻𝑜 20 10000

𝐹𝑆

𝑉1 − 𝑉 𝑉1 𝐻𝑥 15.3 5.262
𝐹𝑆 = = −1= −1= −1= − 1 = 64.92 %
𝑉 𝑉 𝐻1 15 15

𝑃𝑥𝑚𝑎𝑥

𝜎𝑦 𝐻𝑜 𝑛 14 20 2
𝑃𝑥𝑚𝑎𝑥 = [(𝑛 − 1) ( ) + 1] = [(0.637 − 1) ( ) + 1]
𝑛 𝐻𝑥 2 5.262
= 29.70 𝑘𝑔/𝑚𝑚2