MIDDLE EAST TECHNICAL UNIVERSITY
DEPARTMENT OF MECHANICAL ENGINEERING
ME303 MANUFACTURING ENGINEERING
Fall 2024-2025
Tutorial 1
Problem 1
A tensile test specimen has a gage length = 50 mm and its cross-sectional area = 100 mm2 . The
specimen yields at 48000 N , and the corresponding gage lenth =50.23 mm. This is the 0.2% yield point.
The maximum load of 87000 N is reached at a gage length = 64.2 mm. Determine:
a) Yield strength
b) Modulus of elasticity
c) Ultimate Tensile Strength
d) If the fracture occurs at a gage length of 67.3 mm, determine the percent elongation.
e) If the specimen necked to an area = 53 mm2 , determine the percent reduction on area.
(Retrieved from Problem 3.1 of Groover M.P., “Principles of Modern Manufacturing-SI Version”, John
Wiley, 5th Edition)
Solution for Problem 1
a) Yield strength is an engineering quantity, hence calculation of the yield strength should be done
with the initial cross-sectional area of the specimen.
F 48000 N
σy = = = 480 M P a
A0 100 · 10−6 m2
b) When 48000 N is applied, it is indicated that 0.2% yield point. Which means εplastic = 0.002.
Strain at the yield point can be calculated with the given information as follows:
l 50.23
ε = ln = ln = 0.0046
l0 50
Since this value corresponds to total strain and εplastic is given, εelastic can be calculated directly:
ε = εelastic + εplastic → εelastic = 0.0046 − 0.002 = 0.0026
Using this true strain value, engineering strain is:
εeng = eεelastic − 1 = e0.0026 − 1 = 0.0026
Hooke’s law states that
σeng = Eεeng
Since the yield strength calculated in part (a) is the engineering stress,
480 · 106 = E · 0.0026 → E = 184.62 GP a
c) The maximum load is given as 87000 N . Hence, σU T S can be directly calculated as:
FU T S 87000 N
UTS = = = 870 M P a
A0 100 mm2
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d) Percent elongation simply can be calculated by:
l − l0 67.3 − 50
P erc Elong = 100 = 100 = 34.6%
l0 50
e) Percent reduction of area is:
A0 − A 100 − 53
100 = 100 = 47%
A0 100
this measure gives how ductile the specimen is(equal to q, which is ductility, from lecture notes,
Material Properties II, page 13). The higher the percent area reduction, the higher the ductility.
Problem 2
The following load-elongation data was obtained from a sample 50 mm in length and 12.8 mm in
diameter.
Load (kN) Elongation (Extensometer)(mm)
Start 0 0.0
10 0.010
20 0.020
Yield 25 0.025
30 11.2
Max. Load 38 18.7
Fracture 18 24.5
a) What is the UTS?
b) What is the true stress at UTS point?
c) Estimate the strain hardening coefficient (n)?
d) Estimate the strain hardening coefficient (K)?
Solution for Problem 2
a) U T S formula is:
Pmax 38 kN
UTS = = = 295.3 M P a
A0 π6.42 mm2
b) σU T S formula is:
Pmax Pmax Pmax A0 A0
σU T S = = A = = UTS
A A 0 A0
A0 A A
Assuming conversation of volume,
A0 l
A0 l0 = Al → = = eε
A l0
σU T S equation becomes:
l 50 + 18.7
σU T S = U T S = 295.3 = 405.75 M P a
l0 50
c) The strain hardening coefficient, (n), can be calculated using the equation given in the lecture
notes:
l 50 + 18.7
n = εU T S = ln = ln = 0.318
l0 50
d) The strain hardening coefficient (K) can be calculated using previously found σU T S value. Flow
stress is defined as:
405.75
σf = Kεn → 405.75 = K0.3180.318 → K = = 583.76M P a
0.3180.318
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Problem 3
A brass slab of dimensions 40 mm × 1000 mm and height of 50 mm is to be compressed to a final height
of 20 mm in a hydraulic press at room temperature with a ram velocity of 15 mm/min. The material
properties of the workpiece are given as: K = 800 MPa, n = 0.33, C = 14 MPa, m = 0.2.
a) Calculate the press force if µ = 0.2 (consider maximum capacity).
b) Assuming sticking friction over the entire surface and hot working at 800 ◦ C, calculate the press
force required for the process.
Solution for Problem 3
Given parameters:
w = 1000 mm
h0 = 50 mm
h1 = 20 mm
µ = 0.2
a) Volume Consistency and Area Calculation:
V0 = V1 ⇒ (40)(1000)(50) = (2a)(1000)(20)
a = 50 mm
Then, it is necessary to investigate the assumptions for the friction. Note that the friction in the core
is sticking friction up to x = x1 . Also, the friction can be said as sliding friction (Coulomb friction) from
x = x1 to x = a as seen in the figure below:
In our question, let us calculate x1 to realize the case:
h 1
x1 = a − ln
2µ 2µ
(20 mm) 1
→ x1 = (50 mm) − ln → x1 = 4.2 mm
2(0.2) 2(0.2)
Type of friction at the die/workpiece interface:
• Sliding Friction: exponential variation
• Sticking Friction: linear (more severe conditions of friction)
• Mixed Friction: linear at the middle (sticking) and exponential at the edge (sliding)
ME303/Fall 2024-2025/Tutorial 1 Page 3/ 5
This means that friction can be assumed to be sliding friction for this condition. This is because the
sticking friction region is very small compared to the entire surface.
Flow Stress: 0.33
n 50
σ = Kε = (800 MPa) ln = 777 MPa = Y
20
Average Pressure with Sliding Friction:
Pavg h 2µa
= e h −1
Y 2µa
20 2·0.2·50
Pavg = 777 MPa · e 20 − 1 = 1335 MPa
2 · 0.2 · 50
Press Force Calculation:
F = Pavg · A = (1335 MPa)(100 mm × 1000 mm) = 133.5 MN
b) Hot Working with Sticking Friction:
Flow Stress for Hot Working:
V 15 mm/min 1
σ = C ε̇m , ε̇ = = · = 0.0125 s−1
h 60 20 mm
σ = 14 MPa · (0.0125)0.2 = 23.2 MPa = Y
Average Pressure with Sticking Friction:
Pavg 0.5a
=1+
Y h
0.5 × 50
Pavg = 23.2 MPa · 1 + = 52.2 MPa
20
Press Force Calculation:
F = Pavg · A = (52.2 MPa)(100 mm × 1000 mm) = 5.22 MN
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Problem 4 (NOT INCLUDED IN MT1)
An axisymmetric upsetting process is carried out on an annealed cylindrical steel workpiece at room
temperature. The original diameter of the specimen is 50 mm, and the initial height is 75 mm, which
is reduced to 60 mm after upsetting. The associated flow equation is provided as σf = 600ε0.3 MPa.
Assume sliding friction with a coefficient of 0.20 between the die and the workpiece.
a) Determine the equivalent strain.
b) Calculate the average interface pressure at the end of the process.
c) Find the upsetting force at the end of the process.
Solution for Problem 4
Given parameters:
d0 = 50 mm
h0 = 75 mm
h1 = 60 mm
K = 600 MPa
n = 0.3
a) Equivalent Strain:
h0 75
εeq = ln = ln = 0.223
h1 60
b) Final Diameter Calculation using Volume Constancy:
r r
πd20 πd21 h0 75
· h0 = · h1 ⇒ d1 = d0 = 50 · = 55.9 mm
4 4 h1 60
Average Interface Pressure with Sliding Friction:
Since the average interface pressure is asked for the instant at the end of the process, the parameters
at that instant should be used. For sliding friction assumption, it is calculated as follows:
2
Pavg 1 h 2µR 2µR
= e h − −1
Y 2 µR h
d1
Assuming R = 2 = 27.95 mm:
2
0.3 1 60 0.2×27.95 0.2 × 27.95
Pavg = (600 × 0.223 )× e 60 − − 1 = 407.5 MPa
2 0.2 × 27.95 60
c) Upsetting Force Calculation:
The upsetting force at the end of the process is determined by the average pressure and the relevant
area:
πd21 π(55.9)2
F = Pavg · = (407.5 MPa) · = 1 MN
4 4
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