SOLUTION MANUAL

FOR

by W. F. Hosford and R. M. Caddell

 CHAPTER 1

1-1 I1 = 10 + 5 + 7 =32, I2 = -(50 + 35 + 70) + 9 + 4 + 16 = -126

I3 = 350 - 48 - 40 - 80 - 63 = 119
3 - 222 +126 - 119 = 0
trial and error solution gives one root as = 13.04. Factoring out = 13.04 gives 2 -
8.96 + 9.16 = 0, = [8.96 (80.28 - 36.64)]/2
1 = +13.04, 2 = +7.785, 3 = +1.175

1-2a) x = F/[(/4)d2] = 2x104/[ (/4)22] = 6,350 psi

y = z = yz = zx = 0, at the surface, xy = 16T/d3 = 16.104/(8) =
6,350 psi
1, 3 = x/2 (1/2)( x2+4xy2)1/2 = {6.35 (6.352 +4.6.352)1/2]/2
1 = 10,250 psi, 3 = -3,900 psi, 2 = 0

c) max = (1/2)(1 - 3) = 7,080 psi

ex = e2 = (1/E)[2 - ( 3 + 1)] = (1/E)[2 - (22)] = (2/E)(1-2)

Since < 1/2 for metals, ex = e2 is positive and the tube lengthens.
1-4 Area = 4/ in2
For rod a, 1 = 10,000/(/4) = 12,750 psi, 2 = 3 = 0, so
max = 1/2 = 6,380 psi
For rod b, 1 = 12,750 - 5,000, 2 = 3 = 0, so
max = (1 - 2/)2 = [7,750 - (-5000)]/2 = 6,380 psi. Both have the same shear
stresses

1-5 x = Pr/t = 30.1/0.01 = 3000 psi

y = x/2 + 100/(dt) = 1500 +1590 = 3090 psi
z = 0, for steel E = 30x106, = 0.3
ex = (1/E)[x - y] = (3090-900)/30x106 = 73xx10-6
ey = (1/E)[y - x] = (3000-927)/30x106 = 69xx10-6
ez = (-/E)(x + y) = -1827/30x106 = -61xx10-6

1-6 Let the "two" gage be on the x' axis.

a) ex'x' = exxl2x'x + eyyl2x'y xylx'xlx'y
where lx'x = cos30 = 3/2, lx'y = cos 60= 1/2
Substituting the measured strains ( x10-6),
3500 = 3000( 3 /2)2 + 1000(1/2)2 + xy( 3 /2)(1/2)
xy = (4/ 3 ){3500-[3000( 3 /2)2 + 1000(1/2)2]} = 2,309x10-6
b) e1,e2 = (ex + ey)/2 [(ex - ey)2 + xy2]1/2/2
e1,e2 = (3000 +1000)/2 [(3000 - 1000)2 + 2,3092]1/2/2
e1 =3530x10-6, e2 = 470x10-6, e3 = 0

pressure: x = Pr/(2t) = 20.1/0.02 = 1000 psi, y = 2x = 2000 psi

torque: xy = (16doT)/[(do4-di4)] =16.2.200/[(24 -1.984)] = 3231 psi
a) Using the Mohr's circle equations,
tan2 = xy/[(x -y)/2] = 3231/500 = 6.462; = 40.6
(or 180 - 40.6 = 139.4)
b) 1,2 = (x + y)/2 [(x - y)2 + 4xy2]1/2/2
= (1000+2000)/2 [(1000-2000)2 + 4. 32312]1/2/2
1 = 4769 psi, 2 = -1769 psi, 3 = 0
c) max = [4769-(-1769)]/2 = 3269 psi

1-8 1,2 = (x + y)/2 [(x -y)1/2 +4xy2]1/2/2 = A B where B = max

max = B = 1 - A, and A = 2 + B
max = 1 - (2 + B) = B, so 1 - 2 = 2B = 2max
Therefore max = (1 - 2)/2

1-9a) If xy is given as 0.004, plot points ( xy =0.002, ey = 0.002) and (-xy = -

0.002, ex = 0.005)

b) Using eq. (1-37), e1,e2 = (.005 + .003)/2 [(.005 - .003)2 + .0042]1/2/2

e1 = 0.004 + 0.022 = 0.0062
e2 = 0.004 - 0.022 = 0.0018 (agrees with Mohr's circle plot)

1-10 For constant volume, AoLo = AL or L/Lo = Ao/A

= Ln(L/Lo) = Ln(Ao/A) = Ln[(Do2/4)/(D2/4)] = Ln(Do/D)2 = 2Ln(Do/D)
r = 1-A/Ao or Ao/A = 1/(1-r) so = Ln[1/(1-r)]

1-11a) Let x be the length direction, y be parallel to the bend axis and z be the
thickness direction. The 10 in. width is so large compared to the thickness, that plane
strain (ey = 0) can be assumed. Taking z = 0, and
ey = 0, ey = 0 = (1/E)[y - x]; y = x
and as in Ex. 1-11, ex = t/(2R) = (1/E)[x - 2x] = x(1 - 2)/E
x = tE/[(2R)(1 - 2)] = 30x106(1/16)/[2.40(1-.09)] = 25,700 psi
y = x = 0.3. 25,700 = 7,730 psi, z = 0
b) Now y = 0, so x = Et/2R = 30x106(1/16)/80 = 23,400 psi

1-12 ex = (1/E)(x - y) = 0.003 = 1/107(x - 0.3y)

ey = 0.001 = 1/107(y - 0.3x)
solving simultaneously x = 6600 psi, y = 12,000 psi
ez = (1/E)[0 - (x +y) = (1/107)[0 - .3(6600 +12000)] = -.00056
1-13 w = 1de1 +2de2 +3de3 = (1/2)(1e1 +2e2 +3e3)
e1 = (1/E)[1 - (2 + 3)] etc.
w = (1/2)(1/E){1[1 - (2 + 3)] + 2[2 - (3 + 1)] + 3 [3 - (1 + 2)]}
= (1/2)(1/E)[(12 + 22 + 32 - 2(23 + 31 + 12 )]
= (1/2)(1/105x103){0.302 + 0.252 + (-0.20)2 -(2/3)[0.25.(-.20) + (-.20)..30 + .30..25]}
= 1.028x10-6MJ/m3 = 1.028J/m3.

1-14 e2 = 0, 3 = 0, 1 = 40 ksi = 275.8 MPa , 2 = 1 = 0.33x40 = 13.20 ksi

= 91 MPa
a) e1 = (1/205)[0.2758 - 0.33(0.091)] = 0.0012, e2 = 0,
e3 = (1/205)[0 - 0.33(.2758 + 0.091)] = -0.0059
b) w = (1/2)(1e1 +2e2 +3e3) = (1/2)(1e1 +2.0 +0.e3) = (1e1)/2 =
275.8.0.0012/2 = 0.1655 MPa or 165.5 kJ/m3. (24 in.lb/in.3)

1-15 a) The initial diagonal = 2 = 1.414214 and for the small deformation,the final
diagonal becomes (.9902 + 1.012) = 1.41428284
so x' = ln(1.41428284 /1.414214) = 0.000049997
b) x = Ln(1.010/1) = 0.0099503 and y = Ln(0.990/1) = -0.0100503
taking the angle, , between the x' and x (or y) axes as 45,
x' = lx'x2x + lx'y2y = (1/2)(0.0099503) + (1/2)(-0.0100503)
= 0.000050002 which agrees very closely.
c) For the large deformation, the diagonal becomes (1.52 + 0.72) = 1.65529
so calculating the strain from this, x' = Ln(1.65529/2) = 0.1574
The strains on the edges are x = Ln1.500 = 0.40546, and y = Ln0.700 = -.35667.
Using the strain transformation equation,
x' = lx'x2x + lx'y2y = (1/2)( 0.40546) + (1/2)(-.35667) = 0.2439 which does not
agree with x' = 0.1574 calculated from the specimen dimensions. (The reason is that
with large strains, the angle changes with deformation)

CHAPTER 2

2-1 Let x = 20,000/2 = 10000, and y = 10,000/2 = 5000.

a) The difference between the stresses x and y is not great enough so that
(10,000 -5000)/2 = 2500 < k = 20,000 can cause yielding. Therefore these stresses
must be 2 = x = 10000, and 3 = y = 5000 and the unknown stress must be 1.
Setting (1 - 3)/2 = k,
1 = 2k + 3 = 40,000 + 5000 = 45000 psi
F1 = (2in.2)(45000 psi) = 90,000 lbs.
b) Now 3 = x = -10000, and 2 = y = -5000, so with (1 - 3)/2 = k, 1 =
2k + 3 = 40,000 + (-10,000) = 30,000 psi, F1 = 60,000 lbs

2-2 The ratio of the tube diameter to wall thickness is very large, so it can be
treated as a thin wall tube. The stress caused by the pressure can be found by x- and
y- direction force balances.

From pressure, x = Pd/(2t) = 60P and y = Pd/(4t) = 30P. The stress caused by the
axial load is y = F/(dt) = -500/(.3.0.025) = -2142 psi, so the total stress, y = 30P -
2142 psi.
a) x = 60P = max is the largest stress, y = -2142 psi and z = 0. There are
two possibilities which must be checked.
i. If z < y, z = min, and yielding will occur when 60P-0 = Y, or P=Y/60
ii. If y < z, y = min, and and yielding will occur when
60P-(30P-2142) = Y, or 30P = Y + 2142, P = (Y+2142)/30.
Yielding will occur when the smaller of the two values is reached, and therefore the
smaller one is appropriate. P=Y/60 = 40,000/60 = 667 psi
b) Substituting into eq. 2-12 (in ksi),
2(40) = [60P-(30P -2142)]2 +[(30P -2142)-0]2 + [0-60P]2
2
5400P2 -3190.8 = 0, P = 0.769 ksi or 769 psi.

2-3 In the spherical ends, a force balance gives, x (=y) = Pd/(4t), z = 0

In the cylindical section a force balance gives x = Pd/(2t), y = Pd/(4t)

(= x/2), z = 0, so this section has the largest stress and is the critical region.

a) max -min = 2k, Pd/(2t) -0 = 2k, t = Pd/(4k) = 5.48/4.80 = 0.75 in.

b) (x/2- 0)2 + (0 - x)2 + (x - x/2)2 = 6k2, (3/2) x2 = 6k2,
x = 2k = Pd/(2t), t = Pd/(4k) which is identical to a) so t= 0.75 in.
2-4 3 = 0, 1,2 = /2 (2 + 42)1/2/2. Note 2 < 0 so 2 = min Tresca: Y =
max - min = 1 - 2 = 2(2 + 42)1/2/2; Y = (2 + 42)1/2
Mises: (2-3)2 + (3-1)2 + (1-2)2 = 2Y2,
Letting 1 = a + b, 2 = a - b, and 3 = 0, the Mises criterion is:
[(a-b)-0]2 + ([0-(a+b)]2 + [(a+b)-(a-b)]2 = Y2
(a2 -2ab +b2) + (a2 +2ab +b2) + 4b2 = 2a2 +6b2 =2Y2; a2 + 3b2 = Y2
(/2)2 + 3[(2 + 42)1/2/2]2 = Y2, (1/4)2 + (3/4)2 + 32 = Y2
2 +32 = Y2; Y = (2 + 32)1/2

2-5 z = 0, y = - x, x = 0, z = (1/2)(x + y) = y/2

a) = {2/3(x2 + y2 + z2)}1/2 = 2/3 2y = (2 3 )y
b) = (1/2)[(y - z)2 + (z - x)2 + (x - y)2 ]1/2 =
= (1/2)[(y - y/2)2 + y/2 - 0)2 + (0 - y)2 ]1/2 =
= (1/ 2)y(3/2)1/2 = (3/2)y
c) w = d = (3/2)y(23)dy = ydy (this makes sense since we can also
write w = (xdx) + (ydy) + (zdz) = ydy because x = 0 and dz = 0)
d) = K n, substituting = (3/2)y and =(23)y,

3/2y = K[(23)y]n; y = K(23)n+1yn

2-6 a) Yes. The value of the left hand sides are not affected if each principal stress
is increased the same amount.
b) First find the constant C. Consider an x-direction tension test. At yielding, x
= 1 = Y, y = z = 2 = 3 = 0. Therefore (1 - 2)> (2 - 3) so criterion I applies,
and C = (1 - 3) + (1 - 2) = 2Y Therefore C = 2Y.
We can also think about an x-direction compression test. At yielding, x = 3 = -Y,
y = z = 2 = 3 = 0. Therefore (2 - 3)>(1 - 2)> so criterion II applies, and C =
(1 - 3) + (2 - 3) = -(-2Y) or again C = 2Y.
Now consider several loading paths:
In region A, x = 1, y = 2, z= 3 = 0 and x >2y so (1 - 3) >(1 - 2)
Therefore criterion I, (x - 0) + (x - y) = 2Y, or x = Y + y/2
In region B, x = 1, y = 2, z= 3 = 0 but x <2y so (1 - 3)<(1 - 2)
Therefore criterion II, (x - 0) + (y - 0) = 2Y, or x = 2Y - y
In region C, y = 1, x= 2, z= 3 = 0 but y <2x so (1 - 3)<(1 - 2)
Therefore criterion II, (y - 0) + (x - 0) = 2Y, or y = 2Y - x
In region D, y = 1, x = 2, z= 3 = 0 and y >2x so (1 - 2) >(2 - 3)
 Therefore criterion I, (y - 0) + (y - x) = 2Y, or y = Y + x/2
In region E, x = 1, y = 3, z= 2 = 0 and (1 - 2) >(2 - 3)
Therefore criterion I, (x - 0) + (x - y) = 2Y, or x = Y + y/2
In region f, x = 1, y = 3, z= 2 = 0 so (1 - 2) >(2 - 3)
Therefore criterion I, (x - 0) + (x - y) = 2Y, or x = Y + y/2
Plotting these in the appropriate regions, and using symmetry to construct the left
hand half:

c) i. For plane strain (y = 0) and x > 0, The normal to the locus is at the corner
between A and B regions. Both x = Y + y/2 and x = 2Y - y must be satisfied.
Solving simultaneously, x = (4/3)Y and y = (2/3)Y
ii. Axisymmetric flow with y = z = -(1/2)x with x > 0, is satisfied everwhere in
Region I, so x = Y + y/2, with (2/3)Y x (4/3)Y

2-7a) m = (15 + 10 + 5)/3 = 10 and m = (10 + 5 + 0)/3 = 5

b) x' = 15 -10 = 5 and x' = 10- 5 = 5
y' = 10 -10 = 0 and y' = 5 - 5 = 0
z' = 5 -10 = -5 and z' = 0 - 5 = -5
c) i' = 5 + 0 -5 = 0 and i' = 5 + 0 -5 = 0
d/t = 60 so this can be regarded as a thin wall tube. For this solution, stresses will be
expressed in ksi.
F/A = 2/(dt) = 2/(x3x0.05) = 4.244 ksi
T = (dt)(d/2); = 2T/(d2t) = 2x2./(320.05) = 2.829 ksi
x = Pd/(2t), y = Pd/(4t) + 4.244 = x/2 + A, where A = 4.244 ksi
a) For Mises, substituting z = xy = yz = zx = 0 into the yield criterion, Eq. (2-12)
2Y2 = (y - z)2 + (z - x)2 + (x - y)2 + 6xy2
2Y2 = y2 + x2 + (x - y)2 + 6xy2 = 2[y2 - xy + x2] + 6xy2
Y2 = y2 - xy + x2 + 3xy2
Substituting y = x/2 + A,
(x/2 + A )2 - (x/2 + A )x + x2 + 3xy2 - Y2 = 0
x2(1/4 -1/2 + 1) + x(A - A) + (A2 + 3xy2- Y2) = 0
(3/4)x2 + (A2 + 3xy2- Y2) = 0
x2 + B = 0 where B = (4/3)(A2 + 3xy2- Y2)
substituting B = (4/3)(4.2442 + 3x2.829 2- 202) = -2.098
x2 = 2.098, x = 45.8, x = Pd/(2t),
P = (2t/d)x = 45.8(2x0.050/3) = 1.528 ksi
b) For Tresca, we must find the principal stresses.
1,2 = (x + y)/2 (1/2)[(x - y)2 + 4xy2]1/2
Substituting y = x/2 +A,
1,2 = (3/4)x + A/2 (1/2)[(x/2 - A)2 + 4xy2]1/2 =
= (3/4)x + A/2 (1/2)[x2/4 - Ax + A2 + 4xy2]1/2
1 = (3/4)x + A/2 + (1/2)[x2/4 - Ax + A2 + 4xy2]1/2
2 = (3/4)x + A/2 - (1/2)[x2/4 - Ax + A2 + 4xy2]1/2
There are two possibilities: 2 > 0, and 2 < 0.
1st assume that 2 > 0. Then 1 - 0 = Y,
(3/4)x + A/2 + (1/2)[x2/4 - Ax + A2 + 4xy2]1/2 = Y
(3/4)x + A/2 + (1/2)[x2/4 - Ax + A2 + 4xy2]1/2 = Y
(3/4)x + 4.244/2 + (1/2)[x2/4 - 4.244x + 4.2442 + 4x2.829 2]1/2 = 40
(3/2)x + 4.244 + [x2/4 - 4.244x + 49.855]1/2 = 80
[x2/4 - 4.244x + 49.855]1/2 = 75.756 -(3/2)x2
x2/4 - 4.244x + 49.855] = [75.756 -(3/2)x]2 = 5738.9 -227.26x +2.25x2
x2[0.25 - 2.25] + [-4.244 +227.26]x + 49.855 - 5738.9 = 0
2x2 -223.3x + 5689 = 0; x = {223.3 [223.32 -4x2x 5689]1/2}/(2x2) =
55.85 16.49,
x = 72.34 or 39.36, The smaller value is correct
Then P = (2t/d)x = 39.36(2x0.050/3) = 1.312 ksi
Now we must check to see whether 2 > 0. Substituting A = 4.244, = 2.829 and x =
39.36 into
2 = (3/4)x + A/2 - (1/2)[x2/4 - Ax + A2 + 4xy2]1/2
2 = (3/4)x39.36 + 4.244/2 - (1/2)[39.362/4 - 4.244x39.36 + 4.2442 +
+ 4x2.829 2]1/2 = 31.48. Therefore the solution for 2 > 0 is appropriate.

2-9 a) pure shear: 1 = -3 = max, 2 = 0.

= (1/2)(12 + 12 + 412)1/2 = 31, so = 3max.

b) uniaxial tension, 2 = 3 = 0, 1 > 0. max = 1/2

= (1/2)(12 + 0 + 12)1/2 = 1, so 1 = 2max

c) For 1 > 1 > 1, max = (1 - 3)/2

= (1/2)[(2 - 3)2 + (3 - 1)2 + (1 - 2)2]1/2,

If 2 = 3, 1 = 2 max; if 2 = 1, 1 = 2 max. For 1 > 1 > 1, 3max < 1 <

2max [The 3 value occurs for 2 = (3 + 1)/2, i.e. plane strain.]

2-10 a) Substituting 2 = 0, 3 = -1/2 into the flow rules (Eq. 2-31),

d1/d2 = [1-(1/2)( -1/2)]/[0 - (1/2)( 1- 1/2)] = (5/4)/(-1/4) = -5
b) max = (1 - 3)/2 = (3/4) 1.
2 2 = (2 - 3)2 + (3 - 1)2 +(1 - 2)2

2 2 = [(-1/2)2 + (-3/2)2 + 1]12 = (7/2)12; 1 = (4/7)1/2

max = (3/4) 1 = (3/4)(4/7)1/2345 = 195.6 MPa

c) now max = (1 - 2)/2 = 1/2;
2 2 = [(1/2)2 + (1/2)2 + 1]12 = (3/2)12; 1 = (4/3)1/2

max = 1/2 = (1/2)(4/3)1/2345 = 199.2 MPa

2-11a) Using the flow rules (Eq. 2-31),

d1/d3 = [60-(0+30)/2]/[0 -(30+60)/2) = 45/(-45) = -1
b) No change; The value of each term in the flow rules is unchanged.

2-12 a) With von Mises, (2 - 3)2 + (3 - 1)2 + (1 - 2)2 = 2Y2,

{[0.3-(-0.5)]2 + (-.5-1) + (1-0.3)2}12 = 2Y2, 1 = Y[2/( )
b) With Tresca, max - min = Y = 1- 3 = [1 - (-0.5)]1;
1 = (2/3)Y = (2/3)300 = 200 MPa
b) dw = 1d1 + 2d2 + 3d3 = 1d1 + 2.0 + 0.d3 = 1d1
or w = 1d1
c) 2 is m and therefore does no work, 3 = 0, and therefore does no work so only
1 does work.

2-14 Let x be the hoop direction, y the axial direction and z the radial direction.
With the thin wall tube, y = (1/2)x, z = 0. Substituting in the flow rules, dy = d[y-
(z + x)/2] = d[(1/2)x -(0 + x)/2] = 0.
Since dy = 0, there is no length change.

2-15a) First divide stress space into sectors according to the relative size of the
Mohr's circles and apply the proposed yield criterion to each.
 b) Normality says that this condition (dy = 0 with dx > 0) can only occur at the
corner of regions A and B. Here y = x/2

2-16a) The two principal directions in the plane of the surface are parallel to the
major and minor diameters. 1 = Ln(1.195/1.000) = 0.178,
2 = Ln(0.975/1.000) = -0.0253. The ratio of the strains, 2/1 = with
3 = 0, is given by the flow rules as
2/1 = = (2 - 1/2)/(1 - 2/2) = ( - 1/2)/(1 - /2). Solving for ,
= ( +1/2)/(/2 + 1).
Substituting = -0.0253/0.178 = -.142, = (-.142 +.5)/(-.142/2 +1) = 0.385
b) From constant volume, 3 = -1 - 2 = -0.2035
= (2/3)(12 + 22 + 32)1/2 = (2/3)[0.1782 + (-0.0253)2 + (-0.2035)2]1/2 = 0.2217.

[Check: this is greater than |i|max and less than 1.15 |i|max.]

2-17a) From the general expression for the flow rules (Eq. 2-30),
dij = (df/dij)d, with 3 = 0,
d2 = a[2a-1 + (2 - 1)a-1]d and d1 = a[1a-1 + (1 - 2)a-1]d so
= d2/d1 = [2a-1 + (2 - 1)a-1]/[1a-1 + (1 - 2)a-1] =
= [a-1 + ( -1)a-1]/[1 + (1 - )a-1]
b) With = -0.142, and a = 6, -0.142 = [5 + ( -1)5 ]/[1 + (1 - )5]
This must be solved by trial and error
If = the RHS =
0 -0.5
0.5 +0.00.4 -0.0626
0.300 -0.1418
0.29 -0.1511
0.299 0.1427
conclusion: = 0.300

[Note that this is quite different from the answer in Prob. 2-16, assuming von Mises.]

CHAPTER 3

3-1 = Ln(l/lo), and e = (l - lo)/lo = l/lo - 1, so l/lo = 1 + e and

= Ln(1 + e). = F/A and s = F/Ao, so Ao = sA, = sAo /A. Substituting Ao/A =
l/lo = 1 + e, = s(1 + e)
These relations assume uniform deformation in the gage section and are therefore
valid only up to the onset of necking.

3-2 a) Y = 2000/Ao = 2000/[(/4)0.3572] = 19,980 or 20,000 psi

b) In this test, the strain at maximum load (necking) is
2ln(do/dmax load) = 2ln(0.357/0.310) = 0.2823. However for virgin material, the strain
at necking would be = n = 0.500. Therefore the amount of prestrain should be 0.500 -
.2823 = 0.2177
c) Since = Kn, K = /n = /0.5. Substituting the yield stress and in the
tension test on the specimen and the strain,
K = 20,000/0.2177.5 = 42,823 psi. The true stress at the ultimate is
u = Knn = 42,823.0.50.5 = 30,280 psi Fu = uAu = 30,280[(/4)0.3102] = 2285 lbs

3-3 = Kn, Substituting = Ln[1/(1-.4)] = 0.5108 = n.

F2/F1 = 2A2/1A1;
A2/A1 = [Aoexp(-n/2)]/(0.6 Ao)= 1.667exp(-.5108/2) = 1.291
2/1 = (K2n)/(K1n) =(1/2)]0.5108 = 0.7018
F2/F1 = 1.291x 0.7018 = 0.906, F2 = 0.906x120,000 = 108,700 lbs

3-4 Maximum load should occur when = n, and = Ln(1 + e) = Ln(1.3) =0.262
so n = 0.262. The true stress at maximum load is = s(1+e) = 340(1.3) = 442 MPa
Substituting for , and n in = Kn and solving for K,
K = /n = 442/0.2620.262 = 628 MPa

3-5 The effective strain for on e cycle is 2x1.154ln(1.05) = 0.1126

For = K n. For the effective stress to rise to 30ksi, the accumulated effective strain

must be =( /K)1/n = (30/25)1/.25 = 2.07.

The required number of cycles is then 2.07/0.1126 = 18.4 or 19

[Note: this solution assumes that the effective strain increments are additive and ignores the
Bauschinger effect. In reality, with reversed strains, one should observe less hardening with reversed
strain, and a tendency for strain hardening to saturate with a very large number of cycles. There is no
way to determine this quantitatively without experimentation.]

3-6 For uniaxial tension, = 1, and = 1, so

w =1d1 = K1nd = Kn+1/(n+1)

3-7 At yielding, 1 = 2 = 40,000 psi, 3 = 0. e2 = e1 = (1/E)[1-1],

e3 = (1/E)[-21], v/v = e1 + e2 + e3 = (1/E)[2-4] =
(40x103/30x106)[2- 4x0.3] = 0.00107

3-8 a) Let z be the direction of compression, x be the elongation direction and y be

the lateral direction (y = 0). Substituting y = 0 and x = 0 into the flow rules, y = 0
= [y -(1/2)(z + x)] ; y -(1/2)z = 0, y = (1/2)z. Now substituting into the
expression for effective stress,
= (1/2)[(y -z)2 + (z )2 + (y)2]1/2
= (1/2)[(-z/2)2 + (z)2 + (z/2)2]1/2 = -(3/2)z
 [The negative root is appropriate because z is compressive and is a positive scalar.]
Similarly, substituting dx = -dz into d = {2/3(dx2 + dy2 + dz2)}1/2
= {2/3 [(-dz)2 + 0 + dz2)}1/2 = -2/3 dz.
[Again the negative root is appropriate because dz is compressive and d is positive scalar.]
dw = d = [- ((3/4))z][ -(4/3) dz.] = zdz.
Substituting y = 0 and x = 0 directly into dw = xdx + ydy + zdz gives the
same answer, dw = zdz
b) Sustituting = 3/2 |z| and = 2/3 |z| into = K n,
|z| = K(4/3)(n+1)/2 |z|n.

3-9 a) Finishing the calculations:

F(kN) D(mm) a(MPa) a/R /a =F/[(/4)D2]2ln(Do/D)(MPa)
0. 8.96 0. 0. 0. 1. 0.
27.0 8.13 520 0.133 0 1. 520.
34.4 7.62 754. 0.263 0 1 654.
40.6 6.86 1099. 0.473 0. 1. 1099.
38.3 5.33 1717 0.978 0.26 0.95 1631.
29.2 3.81 2561 1.65 1.06 0.82 2100.

b. Now plotting:

The corrected curve can be represented by = 1650 0.56

c. w = d = Ken+1/(n+1) = 1650x106Pax0.201.56/(1.56) = 85.9x106Pa

d. If this energy goes to heat the metal, T = Q/(C)
Substituting = 7.87 g/cm3 and C = 0.11cal/goC = 0.46J/goC,
T =[85.9x106J/m3)/(7.97x0.46J/cm3oCx106cm3/m3) = 23.4oC

3-10a) 1= Ln(1 + 0.172) = 0.1587, 2= Ln(1- 0.0431) = -0.0441

= 2/1 = -0.0441/0.1587 = -0.2775
= 2/1 = (2 - (1/2)/[(1/2)2 -1] = ( 1/2)/[(1/2) - 1]
= ( +1/2)/(1+ /2) = 0.258
b) = (1/2)[(2 -3)2 + (3 -1)2 + (1 -2)2]1/2
/1 = (1/2)[2 + 1+ (1- )2]1/2 = (2 - + 1)1/2 = 0.899
c) 3 = - 2 - 1 = -0.1146,
= [(2/3)( 12 + 22+ 32)]1/2 = 0.1639
[Check: this is greater than | i|max = 1= 0.1587, but not more than1.15 1]
d) Substituting = = 0.1639, n = 0.22 and K = 650MPa into = K n,

= 650(0.1639 )0.22 = 436.6 MPa.

/1 = 0.899, so 1 = 436.6 MPa/0.899 = 485.6 MPa

CHAPTER 4

4-1 Instability occurs when dF = 0 which corresponds to d/d = .

a) Substituting d/d = An(B +)n-1 and = A(B + )n,
An(B +)n-1 = A(B + )n, n = (B + ), = n -B
b) Substituting e = exp -1, = A[exp -1]n,
d/d = An[exp -1]n-1exp
Equating d/d = , An[exp -1]n-1exp = A[exp -1]n, exp -1 = n,
= Ln(1+n)

4-2 In the walls of the balloon, x = y = Pr/(2t), z = 0.

P = x(2t)/r. x = (1/E)(1-)x or x = Ex(1-) = 2Ex, P = 2xt/r. For instability, dP
= 0, or (t/r)dx + (x/r)dt -(xt/r2)dr = 0
dx + x(dt/t) - x(dr/r) = 0
Substituting dt/t = dz = -2dx, dr/r = dx, and dx = 2Edx
2Edx + (2Ex)(-2dx) - (2Ex)dx = 0, dx(1 -3x) = 0, x = 1/3.
x = Ln(d/do) = 1/3, d/do = exp(1/3) = 1.395
This is unrealistic. With rubber, d/d actually increases with strain, so the
maximum pressure occurs at a higher strain than calculated here.

4-3 The pressure has no effect on , (see Eq. 2-16) so = t where t is the

tensile stress (= 1 - P). Similarly = t, so if = K n, t = K tn, and instability

will occur just as in a tension test at t = n.

4-4 Here 1 = Pr/t, and 2 = Pr/(2t) and 3 = 0. With 2 = 1/2, the flow rules
predict plane strain, 2 = o, 3 = -1. The effective stress and strain relations give =
(3/4) 1 and 1 = (3/4) , so
(3/4)1 =K( (4/3) 1)n, 1 = K( (4/3))n+11n,
P = 1t/r = 1[toexp(3)]/[roexp(1)] = K( (4/3))n+11n(to/ro)exp(-21).
For maximum P, dP/1 = 0; 1nexp(-21)(-2) + n1n-1exp(-21) = 0
-21 + n = 0, 1 = n/2, = (4/3)1 = (4/3)n/2 = n/3 = 0.25/3 = 0.144

b) 1 = Ln(r/ro), or r = roexp(1), 3 = Ln(t/to), t = toexp(3). At instability, 1 =
(3/4) x0.144 = 0.125, 3 = -1 = -0.125;
r = 2(exp(.125) = 2.266, t = (1/16)exp(-.125) = 0.0552
= 22,000(0.144).25 = 13,560, 1 = 4/3) (13,4560) = 15,660 psi

P = 15,660(0.0552/2.266) = 380 psi

4-5 Let x = axial strain. As the tube lengthens, the walls thin but the
circumference cannot change, so d = 0. This is a case of plane strain. Instability will
occur when F = Ax x reach max, or dF = Ax dx + x dAx = 0
or, dx/x = -dAx/Ax = dlx/lx = dx. Here x = (4/3) and d x = 3/2 d.

Substituting, the condition for instability is,

dx/x = d / = 3/2 d .

With = K n, d / = (nK n-1d )/K n = n d / so n/ = 3/2, = 2/3 n

x = 3/2 = n = 0.25.

F = x Ax = xDt = (4/3) Dtoexp(-x) = (4/3)K nDtoexp(- (3/4) )

= (4/3)x25,000x0.250.2510x0.20 exp(-3/2 x0.25)

= 103,300 lbs

4-6a) For plane strain, y = 0, dx = = dz, d = (2/3)dz. As in the last problem

(4-5) instability occurs when = (2/3)n or z, = n = 0.4.

b) = 50,000(o.46)0.4 = 36,710 psi

4-7 As in problem 4-4, instability occurs when = n/3, so here

= (.2)/3 = 0.115 and 1 = (3 /2) = (3 /2)(.2)/3 = 0.2/2 = 0.100. r = roexp(0.1) =

1.105ro, t = toexp(-0.1) = 0.905to,

4-8 Assume a fixed amount of gas and neglect any temperature changes.
PV = constant, so d(PV) = 0 = PdV + vdP or dP = -PdV/V. V = (4/3)r3, so dV =
4r2dr and dV/V = 3dr/r = 3 dr. Now, dr = d = -det/2, so
d = [(2/3)(dr2 + d2 + dt2)]1/2 = 2dr or dV/V = (3/2)d,

then dP = -P(3/2)d (1)

n
For the sphere, where = K and P = 2rt/r and r = , t = 0,

dP = (2r/r)dt + (2t/r)dr - (2tt/r)(dt/t + dr/r - dr/r) (2)

Here = r = K n, so d / = nd / ,

dr = dr/r = d, dt = dt/t =-2dr = -2 d. (3)

Using (3) in (1)
dP = (2rt/r)[dt + nd / -dr], but d = 2dr and d = -dt so

dP = P[-d + nd / - d /2] = P(n/ - 3/2)d

(4)
Equating (1) and (4), -P(3/2)d = P(n/ - 3/2)d
or n/ = 0 so and instability

is not predicted.

4-9 Let the region with the smaller diameter be designated a and the region
with the larger diameter be b. Using a force balance,
fanexp(-a) = bnexp(-b); a = 2ln(1.9/1.698) = 0.2248,
b = 2ln(2/1.893) = 0.1100, f = (1.9/2)2 = 0.9025.
0.9025(0.2248)n(0.799) = (0.110)n(0.896)
(.2248/.110)n = 1.243; n = Ln1.243/ln2.0455 = 0.304

4-10 f = (0.0297/0.0303) = 0.9802, b = 0.2, a = n

Substituting into fanexp(-a) = bnexp(-b)
0.9802nnexp(-n) = 0.2nexp(-0.2); 0.9802nnexp(-n/.2) - 0819 = 0
by trial and error, n = 0.301

4-11a) Ln a tension test = , and = , so = A -Bexp(-C),

At necking, d/d = , or BCexp(-C) = A -Bexp(-C)

exp(-C) = A/[B(C+1)]; = (1/C)ln[B(C+1)/A]
b) The true stress at the ultimate is
u = A - Bexp[-C(1/C)ln[B(C+1)/A] = A - A/(C+1) = AC/(C + 1)
Su = uexp(-u) = [AC/(C + 1)]exp[(1/C)ln[B(C+1)/A] =
Su = [AC/(C + 1)]exp[(-1/C)ln[B(C+1)/A] = [AC/(C + 1)]/[B(C+1)/A]1/C
Su = C[A/(C + 1)](1+1/C)B-1/C

4-12 a) Necking starts when d/d = . Substituting d/d = 1.35Y and = Y +

1.35Y, 1.35Y = Y + 1.35Y, = 0.35/1.35 = 0.259
b) F1 = F2 so 1A1 = 2A2. Substituting A1 = A1oexp(-1),
A2 = A2oexp(-2). Also 1 = Y + 1.35Y1 and 2 = Y + 1.35Y2,
(Y + 1.35Y1)A1oexp(-1) = (Y + 1.35Y2)A2oexp(-2)
(1 + 1.352)exp(-2) = (A1o/A2o)(1 + 1.351)exp(-1)
With 1 = 0.200 and (A1o/A2o) = 0.99,
(1 + 1.352)exp(-2) = 0.99.1.27.exp(-.20)
(1 + 1.352)exp(-2) = 1.02939
2 must be found by trial and error.
Trial 2 LHS
0.18 1.0382
0.1 1.0270
0.12 1.0306
 0.11 1.0288
0.115 1.02975
0.112 1.02922
0.113 1.0294
0.1129 1.02938

CHAPTER 5

5-1 a) Assume the thickness are chosen so both materials can sustain the same
force at yielding. Then t2Y2 = t1Y1, or t2/t1 = Y1/Y2. Since both steels have the same
density,
W 2/W 1 = t2/t1 = Y1/Y2 = 35/60 = 0.583.
% weight reduction = (W 1-W 2)/W 1 = 1- W 2/W 1 = 1 - 0.583 = 41.7%
b) Now W 2/W 1 = [Y2(104/10-3).03]/[Y1(104/10-3).01] = (Y1/Y2)(107).03-.01 =
1.380(Y1/Y2) = 1.380.0.583 = 0.805
% weight reduction = 1 - 0.805 = 19.5%

5-2 a) Substituting n = 0.15, f = 0.318/0.322 = 0.9876 and a = n = 0.15 into

fanexp(-a) = bnexp(-b),
0.9876(0.15)0.15exp(-0.15) = b0.15exp(-b)
b0.15exp(-b) = 0.6395
Solving by trial and error, b = 0.096 [This agrees with fig. 4-8]
b) Substituting m = 0.15 and a = 0.50 into eq. (5-11)
exp(-b/m)-1 = f1/m [exp(-a/m) -1], and solving, b* = 0.327.
For a = , b* = -mln(1-f1/m) = -0.15ln(1- 0.98761/.15) = 0.379

5-3 a) l/lo = 1/cos75 = 3.864. elongation = l/lo - 1 = 2.864 = 286 %

b) The average strain = Ln3.864 = 1.352. First assume that this is the largest
strain, so a = 1.352.
tb/ta = 1.20 = [tboexp(-b)]/[taoexp(-a)] = (1/f)exp(-b)/exp(-a)
exp(-b) = 1.2(0.98)exp(-1.352) = 0.3043, b = 1.897
Now substituting into exp(-a/m) - 1 = f1/m[exp(-b/m) - 1] exp(-1.352/m) - 1 =
(0.98)1/m[exp(-1.897/m) - 1]
solving by trial and error, m = 0.577
The other extreme assumption is that b = 1.352. Then following the same procedure,
exp(-1.897/m) - 1 = (0.98)1/m[exp(- 1.352/m) - 1]
by trial and error, m = 0.66. The correct answer must be between 0.577 and 0.66. A
reasonable estimate is m = 0.62

5-4 m' = d/dln(`), d = m' dln(`) = m'(d`/`)

also = C`m so d = mC`m-1d`.
Equating m'(d`/`) = mC`m-1d`, m' = mC`m = m
Using points from fig 5-15, m = 0.05 at = 30 ksi,
m' = 30(0.05) = 1.5 ksi
Also for m = 0.022, = 60 ksi so m' = 60(0.022) = 1.32 ksi
and for m = 0.012, = 100 ksi so m' = 100(0.012) = 1.20 ksi
These average to m' = 1.3 ksi

5-5 a) ` = Aexp[-Q/(RT)] so `2/`1 =exp[-(Q/R)(1/T2-1/T1)] and Q = R

ln(`2/`1)/(1/T1-1/T2) = R ln`/(1/T)
The slope of the 2500 psi line at 400C is ln`/(1/T) = Ln100/0.22x10-3 =
20,900C
So Q = 8.31x20,900 = 174x103 J/mole or 174 kJ/mole
b) For = C` m, m = Ln(2/1)/ ln(`2/`1). At 400C, = 4000 psi gives ` =
4/min. and = 1500 psi gives ` = 0.25/min. Substituting,
m = Ln(4000/1500)/ ln(4/0.25 ) = 0.354

5-6 a) Sustituting f = 0.98 and m = 0.5 into b* = -m ln(1-f1/m),

b* = -0.5 ln(1-0.982) =1.1615, l/ lo = exp(b) = exp(1.1615) = 5.02 (502 %)
b) With f = 0.75 and m = 0.8 , b* = -0.8 ln(1-0.751/.8) = 0.958
l/ lo = exp(b) = exp(0.958) = 2.06 (206 %)

5-7 T = a /(C) so = CT/a. Untempered Martensite can only be

formed from austenite, so austenite must have formed in the shear bands. Thus the
temperature must have risen to at least 750C. Assuming an initial temperature of
20C, T = 730C. Substituting = 7.87Mg/m3,
C = 0.46 kJ/kg.C and = 1, = 1.53. Assuming pure shear, = 2 = 3.06.

5-8 a) For a constant `, must be constant (i.e. = C`m) but = P/(2t) (Eq. 3-
21). Although t decreases as the bulge is formed, its change is small compared with
the change of which decreases from at the start to the radius of the dome.
Therefore P must increase gradually from 0 at the start to a maximum at the
hemispherical shape, roughly in proportion to 1/.
b) For a 20 in. dia. dome, the pressure is 1/10 that for a 2 in. dome since P is
roughly proportional to 1/.

5-9 a) Since ` = Aexp[-Q/(RT)], `2/`1 =exp[-(Q/R)(1/T2-1/T1)] and

Q = R ln(`2/`1)/(1/T1-1/T2) = 8.31 ln2/(1/563-1/573)
Q =186x103 J/mole or 186 kJ/mole
b) m = Ln(2/1)/Ln(`2/`1) = Ln(1.018)/Ln8 = 0.0086
5-10 a) For = C` m, 2/1 = (`2/`1)m, and m = Ln(2/1)/ ln (`2/`1).
Substituting 2 = 20 MPa at `2 = 2.5x10-3 and 1 = 10 MPa at `1 = 3x10-5, m =
Ln(20/10)/ ln(2.5x10-3/3x10-5) = 0.156
b) Since f() = `exp[-Q/(RT)], Comparing two combinations of temperature and
strain rate which correspond to the same stress,
`2exp[-Q/(RT2)] = `1exp[-Q/(RT1)], `2/`1 =exp[-(Q/R)(1/T2-1/T1)]
ln(`2/`1) = (Q/R)(1/T1-1/T2)
Q = R ln(`2/`1)/(1/T1-1/T2)
Comparing points at = 14 MPa, `2 = 8x10-4 at T2 = 810 + 273 = 1083 K, and `1
= 4.4x10-5 at T1 = 700 + 273 = 973 K
Q = 8.31 ln(8x10-4/4.4x10-5)/(1/973 - 1/1083) = 231,000 J/mole
Q = 231kJ/mole

5-11 Substituting m = 1, f = 0.9 and a = Ln(1.2) = 0.1823 into

exp(-B/m) -1 = f1/m[exp(-A/m) -1],
exp(-B) -1 = .9(1/1.2-1), exp(-B) = .850, B = .162
LB = LBoexp(B) = 1.exp(.162) = 1.176 in.

5-12 This data very nearly describes a hyperbola, m = A/. If is expressed in

MPa, A 1 so m 1/.

5-13 In a pure shear test, the the effective stress and strain rate for Tresca
criterion are = 2, and ` = |i|max = /2, so /` = 4/ = 4, so

= 4` .

CHAPTER 6

6-1 In drawing, the homogeneous work per volume wa = the drawing stress, d,
so d = d = Kn+1/(n+1) assuming = 1. The tensile stress required to induce a

strain 1 is 1 = K1n. Comparing, d/1 = 1/(n+1). The maximum uniform strain in

tension is n, so the ratio d/1 < 1.

6-2 The maximum drawing reduction occurs when d = = 1.

d = (1/) d = (1/)Kn+1/(n+1) = = K n

= (n+1) = max. If = 1, max = 1.5 and r = 0.78. If = 0.6, r = 0.59

[Note that the largest reduction that could be made by tensile elongation is = n = 0.5 (r = 0.39).
6-3 a) Pext = (1/)wi = /. Substituting = 10 ksi,

= Ln(Ao/Af) = 2 ln(Do/Df) = 2 ln4, and = 0.5.

Pext = (1/0.5).10ksi.2 ln4 = 55.5 ksi (103psi)

(b) Assuming Mises (or Tresca), for axisymetric flow
(2 = 3 = -(1/2)1, so 2 = 3, and 1- 2 = . Therefore

2 = 1 - = 10 - 55.5 = -45.5 ksi. Plat = 45.5 ksi.

(c) Using the thin-wall approximation,

2twall = dp, or t = dp/(2wall). Taking p = 45.5 ksi, wall = 100, ksi and d = 4 in., t =
4x45.5/(2x100) = 0.91 in.
Note: This is not really a thin wall tube, so the answer is not exact.
6-4 a) Friction and redundant deformation.
b) Since both tend to lower the efficiency, , they would lower * and therefore
rmax.
c) Since redundant deformation induces strains larger than the homogeneous
strain, i, the yield and tensile stresses are higher and the ductility lower than would
result from homogeneous deformation alone. Friction seems to have little effect on
the final properties.

6-5 To avoid yielding in the bar, P < Y, and P = (1/) d = (1/)Y.

At the limit (1/)Y = Y, so max = . = 2 ln(Do/D1), D1/Do = exp(-/2), D/Do = 1-

D1/Do = 1 - exp(-/2) = 1 -exp(-/2) = 1 - exp(-0.25) = 0.221 (22.1%)
6-6 Since w = 0, this is plane-strain deformation.
= -t = Ln(0.25/0.20) = 0.223. = (2/3)(0.223) = 0.258

wa = (1/) d = (1/0.75)(100,000)(0.258)1.2/1.2 = 21,860 in.lb/in3

The rate of work is

wa.velocity.cross section = 21,860 in.lb/in3.(1000.ft/min)(36x0.25in2) =
1.968x108ft.lb/min
Power =1.968x108ft.lb/min/(33000ft.lb/min/HP) = 5,963 HP

6-7 3 = -1 + 3 = -.200 + .125 = -.075

= [(2/3))0.22 + 0.1252 + 0.0752)1/2 = 0.202
[Check: 0.2 < 0.202 < 1.15x0.2]
w = K n+1/(n+1) = 50,000x0.2021.3/1.3 = 4808 in.lb/in3

6-8 To find the minimum number of dies, design using the largest reduction
permissible, i.e. d = 0.6. Assume no work hardening, so that d = (1/).
Substituting, 0.6 = (1/), or = 0.6.
Now note that the depends on . The relation in the graph can be expressed as
graph = A + B. Evaluating A and B, graph = 0.6833 + /3. However
practice = 0.75 graph = 0.75(0.6833 + /3) = 0.6833 + /3.
Substituting, = 0.6 = 0.6(0.6833 + /3) = 0.3075 + 0.15.
 = 0.3075/0.85 = 0.3617 This is the maximum permissible reduction per pass and corresponds to
a diameter reduction such that
ln(An+1/An) = 2n(dn+1/dn) = -0.3617.
Therefore dn+1/dn = exp(-0.3617/2) = 0.8345.
The total number of passes required, N, should be such that
(0.8345)N = 0.010/0.025; or N = Ln(0.010/0.025)/ ln(0.8345) = 5.065 passes. Since
the number of wire drawing passes must be an interger, 6 (six) passes will be
required. It is sensible to make all of the passes with the same reduction (same
strain). Therefore the strain per pass should be total strain/6 = 2 ln(0.025/0.010) =
0.305. This corresponds to a diameter reduction of
(dn+1/dn) = exp(-.305/2) = 0.858. (14.16% diameter reduction per pass)

6-9 In this case, the maximum drawing stress is

d(max) = Su = K(n/e)n so (n/e)n = (1/)*n+1/(n+1),
* = [(n+1)(n/e)n]1/(n+1)

6-10 d = wa = (1/)d = (1/)(B + C)d = (1/)[B + (C/2)2]

At the drawing limit, d = , (1/)[B + (C/2)2] = (B + C)
(1/)C/2)2 + (1/)B C -B = 0
2 + [(2B/C) 2] - 2B/C = 0
= ( -B/C) [(B/C)2 + 2]1/2.
For = 0.75, B = 30,000, C = 10,000, = -2.25 3.09
Only the positive root makes physical sense, so = -2.25 + 3.09 = 0.842

CHAPTER 7

7-1 Eq. (7-14) gives d = Ym[(1 + B)/B][1- exp(-Bh)] where

B = cot = 0.06x7.115 = 0.427. h = Ln(0.125/0.100) = 0.233, Substituting Y, B and
h, d = 50,000(1.427/0.427)[1-exp(-0.427x0.233)] = 15,186
Fd = dA1 = 15,186x10x0.10 = 15186 lbs.
Power = FdV1 = 15,186lbx50ft/min = 759x103ft.lb/min or
759x103ft.lb/min/[33,0003(ft.lb/min)/HP)] = 23 HP

7-2 a) = i/d = Yav/d Substituting eq. 7-14 for d,

= Yav/{Yav[1+B)/B][1-exp(-B)]} = B/(1+B)]/[1-exp(-B)].
Now substituting = Ln[1/(1-r) = 0.223 and = .65,
0.65/0.223 = [B/{(1+B))[1-exp(-0.223B)]}
Solving by trial and error,
B = 0.654 but B = /tan, so with = 6o, = Btan6o = 0.0687
b) Substituting B = 0.654 and = Ln[1/(1-.4) = 0.5108 into
= B/(1+B)]/[1-exp(-B)] = 0.711
c) Sachs analysis ignores the redundant work, so the friction coefficient
calculated to explain the experimental data is too high. This is particularly true for low
reductions where the redundant work is a large fraction of total work. Use of this
friction coefficient for higher reductions then tends to overestimate the actual work
(Hence low predicted efficiency)

7-3 Using Pav = Y + (2/3)kR/h with R/h = 0.475/0.060 and Y = 25,000 and
assuming Tresca so Y = 2k,
Pav = 25,000[1 + (0.475/0.060)/3] = 91.0 ksi
F = PavA = 91.0 x103x(0.4752) = 64,500 lbs.
If von Mises were assumed, Y = 3k so
Pav = 25 +28.87(.475)/(3x.06) = 101 ksi and F = 71,700 lbs

7-4 This approximates plane-strain compression with sticking friction. Using eq. 7-
25, Pav = 2k[1 + b/(4h)] where k = Y/3
and initially b = h = 1 and at the end of compression b = 4, h = 1/2.
a). Substituting final values, F = -20Pav = -20x2(2500/3 )[1 + 2/4x.5]
= -115,500 pounds (the minus sign for compression)
b) W = Fdh; substituting F = -Pavx10b and Pav = 2k[1 + b/(4h)]
W = Fdh = -2k[ 10b[1 + b/(4h)]dh, but b = 1/h (since bh = 1) so
W = 2k[10(1/h)[1 + (1/h)/(4h)]dh = -20k[1/h + (1/(4h3)]dh =
= -20k[ ln(hf/ho) + (-1/8)(hf-2- ho-2)]
Evaluating at ho = 1 and hf = 1/2,
W = -20k[ ln(1/2) - (1/8)(4 -1)]
= 20k[ ln(1/2) - 3/8] = -20k(-1.068)
= 20(2500/3 )(1.068) = 30,800 in-lbs. (2,570 ft-pounds)
c) Height: weight x height = potential energy so
height = (2,570 ft-pounds)/(200 pounds) = 12.8 ft.
d) Ideal work, W i = vol.Y = 10in3.2500psi.1.155. ln(2) = 20,000in-lbs.

= W i/W a = 20,000in-lbs./30,800 in-lbs = 65%

7-5 This is like compression test with sticking friction with b = 0.1,h = 0.02, except
that the signs of the stresses are reversed. For von Mises 2 = 2k = 2Y/3 = 1.155Y;
for Tresca 2 = 2k = Y
Substituting into Pav = 2k[1+b/(4h)],
for von Mises: Pav = 1.155Y[1+.1/.08] = 2.598Y = 39.0 ksi
F = PavA = 39,000x.1x2 = 7,800lbs
for Tresca: Pav = Y[1+.1/.08] = 2.25Y = 33.7 ksi; F = 6,750 lbs
7-6 Since the change in Do is minimal compared with the change of the 0.020 and
0.040 in. dimensions, d 0. Then this is a problem of plane-strain compression with
sticking friction. From eq. 7-25,
Pave = 2k[1 + b/(4h)] where at the end of compression h = 0.010 and
b = 0.080 in.
Tresca Y = 2k = 2000 psi, Pave = 2000[1 + .08/.04] = 6,000 psi
F = PavexA = Pave(Dt) = 6000xx10x0.08 = 15,080 lbs.
Mises, Y = 3k so 2k = 2Y/3 = factor of 1.155 times solution for Tresca. F =
1.155x15,080 = 17,340 pounds

7-7 The force balance analogous to Eq. 7-2 is

xdt = tdx + Pdt + kcotdt = 0
y = -P +ktan, and x - y = 2k, so x =2k - P +ktan, or
P = k(2 + tan) - x = C1-x where C1 = k(2 + tan)
Substituting in the force balance, tdx + [x + P + kcot]dt = 0
tdx + [x + C1 - x + kcot]dt = 0, tdx + [C1 + kcot]dt = 0 or
tdx + C2dt = 0 where C2 = C1 + kcot = k(2 + tan + cot)
Integrating from to to t and x = 0 to d,
d =dx = -C2 ln(t/to) = k(2 + tan + cot) ln(to/t)
d/2k = [1 + (tan + cot)/2] ln(to/t) = h [1 +sin/cos +cos/sin]/2
= h[1 + (sin2 + cos2)/(2sincos)] = (1 + 1/sin2)h

7-8 Consider first the contact area between the rolls and the work.

To increase the spreading, L/w should be as large as possible. The reason that
very little spreading usually occurs in flat rolling is because usually w>>L and the
undeforming metal just outside of the roll gap (at the entrance and exit) constrains
lateral flow of the deforming metal. Here however L/w can be made large enough so
that the constraint from the undeforming material is minimized. Then as L/w is
increased, friction should encourage spreading instead of elongation. (See sketch of
the friction hill below).
 Since L = (Rrho), to increase L, one should try to have
1. large roll radius, R,
2. large reduction, r, per pass. Preferably the reduction should be made in one
pass if possible.
3. With L/h>1, high friction is desirable, because friction will constrain lengthwise
flow more than sidewise flow. (The direction of flow under a friction hill is in the
direction of the hill's gradient.)
4. Front and back tension should be avoided. They would tend to cause lateral
contraction instead of lateral spreading.

Other ideas? Perhaps friction could be made directional by scratching the rolls
parallel to their axes so that would be lower for sliding parallel to the rolls than
perpendicular to them. Note: The engineers at Bell Labs, who had this problem were
able to roll the wire in such a way that the elongation was negligible. They used rolls
that were large (relative to the wire size) and a single rolling pass.

7-9 The strain, 1, can be found from the annular areas,

1 = Ln[(2.4352-22)/(2.3202-22)] = 0.3333
The drawing deformation can be viewed as plane strain, so
= (2/3)e1 = 0.3849; = k n = 25,000( 0.3849)0.25 = 19,690 psi1 = (2/3) =

22,740 psi
From eq. 6-4, Yav = 1/(n+1) = 22,740/1.25 = 18,190 psi
B = mcot. On the outside wall = 30 but on the inside wall, q = 0, so taking an
average ( = 15), B = 0.05cot15 = 0.1866
Substituting into d = Yav[(1+B)/B][1 - exp(-Bh)],
d = 18,190(1.1866)/0.866([1 - exp(-0.866x 0.3333)] = 6975 psi

7-10 Assume Tresca where Y = 2k = 5000 psi

a) If = 0, use eq. (7-11), d = 2kh where h = 2 ln(4/2) = 2 ln2= 1.386
d =5000x 2 ln2 = 6,930 psi
b) For sticking friction, use the solution to prob 7-7,
d = 2k(1 + 1/sin2)h = 5000(1.386)(1 + 1/0.866) = 14,932 psi
c) = 0.20, use eq. (7-14), with Yav = 5000 and B = 0.2cot30 = 0.346
d = Yav[(1+B)/B][1 - exp(-Bh)] = 5000(1.346/0.346)[1-exp(0.346x 1.386)] = 7,410
psi
[Note that if von Mises had been used, Y = 3k so 2k = 5774 psi and the answers are a) 8000; b)
17,500; c) 8560. Also note that the expression for d in part b was not given in text, but it is in problem
7-7. Note also that in all three solutions, d > Y so the reduction could not have been made under these
conditions.]

7-11 a) Pav = [h/(L)][exp( L/h) - 1]o where h = (ho + hf)/2 = 0.0625,

h = ho - hf = 0.25 so L = (Rh) = [4(.025)] = 0.316, o = 20,000,
Substituting, Pav = [0.625/(0.1x0.316)][exp(0.1x0.316/0.0625) - 1]x20,000
Pav = 26,000psi [Note: o is taken as the plane strain flow stress in this problem. This equals 2k for
both the Tresca and Mises criteria.]
b) Here we should use R' instead of R . Equations (7-40) and (7-43) must be
solved simultaneously. to determine the combination of Fs and R' that satisfies both.
Substituting E' = 33x106, R = 4, and h = 0.025 Eq. (7-40) becomes
Fs = (R'/R -1)hE'/16 = (R'/R -1)(0.025)(33x106)/16
= Fs = 1.62x105(R'/4 -1) (a)
and Eq. (7-43) becomes
Fs = (h/){exp[/h)(R'h)1/2]- 1}x20,000
Fs = (0.0625/0.1){exp[(.1/0.0625)(0.025)1/2R' ]- 1} x20,000
Fs =125000[exp(0.253R') -1] (b)
Now using a numerical solution of (a) and (b),
R' = 4.21 and Fs = 8,506. Now substituting into eq (7-42)
Pav = {.0625/[.1(0.25x4.21)1/2]}{exp[(.1/.0625)(4.21x.025)1/2] -1}x20000 = 26,225
psi.
[note that Pav = Fs/(R'h = 26,225 psi. Roll flattening could have been neglected for
these conditions]
c) Using Eq. (7-44) with C = 7 as an extreme,
hmin = 7(0.1)(4)(20,000)/(33x106) = 0.0017 in.
For C = 8, hmin = (8/7)(0.0017) = 0.00194 in.

7-12 Expanding equation 7-14, d/a = [(1+B)/B][1-exp(-Bh)]

exp(-Bh) = 1 -Bh + (Bh)2/2 - (Bh)3/3! .....
Neglecting all of the higher order terms,
d/a = [(1+B)/B][Bh] = (1+B)h, d = ah + Bah
The homogeneous work is ah = wi. The analysis is based on homogeneous
straining so wr = 0. Therefore the term Boh must represent wf
Hence wf/wi = Bah/ah = B = cot. This would lead us to conclude that wf/wi
increases with , decreases with and is independent of h.
[If one more term of the expansion were retained,
exp(-Bh) = 1 -Bh + (Bh)2/2 and substitution gives
d/a = [(1+B)/B][Bh - (Bh)2/2] = (1+B)h - (1+B)Bh2/2 or
d = ah + Bah(1 - Bh/2)
Now wf = ahB(1 - Bh/2) and wf/wi = B - B2h/2
This predicts a slight decrease of wf/wi with h.

7-13 From the Mohr's circle diagram, tan(2) = (2mk)/(P-x) Substituting (P-x) =
2k, tan(2) = (2mk)/(2k) = m, = arctan(m). If m = 1 (max. possible value, = 22.5. If
m = 0.5, 13.2. Note is independent of x, h, L and 2k, but does vary from 0 at the
centerline to a maximum at the surface.

CHAPTER 8

8-1 Using = 30, r = 0.5 and = 80 the relations below Eq. (8-7), VAB* =
Vosin30/sin(80-30) = 0.653Vo
cot = 2(cos30 - cot80) = 1.379, = 35.95
VBC* = VAB*sin80csc35.95 = 0.653 Vo(0.9848)(1.7036) = 1.096Vo
AB = hocsc80 = 1.0154ho
BC = (ho/2)csc35.95 = 0.8518ho
Now, substituting into Eq(8-7),
Pe/(2k) = [1/(2hoVo)][(0.653Vo)(1.0154ho) + (1.096Vo)(0.8518ho)]
Pe/(2k) = 0.798 which agrees with Fig. 8-3

8-2 First constructing the corresponding hodograph:

From analysis of the hodograph, V*AB = (1/3)Vo; V*BC = (2/3)Vo;
V*CD = V*BC = (2/3)Vo; V*ED = 2V*CD = (4/3)Vo;
and from analyzing the deformation field, and CD = DE = 2te and
AB = BC = to = 4te.
The work rate in the field is
`W = k{ABV*AB + BCV*BC + CDV*CD + DEV*DE}
= k{ (1/3)4 + (2/3)4 + (2/3) 2 + (4/3)2}Vote = k24/3Vote.
The external work rate equals `W = dteVe.
Equating and substituting Vo = Ve/4, dteVo(4) = k24/3Vo.
d/2k = 3/3 = 3 = 1.732
[Of course this answer is not possible because a drawing failure would occur if d/2k 1. This
reduction is much too high for drawing!]

8-3 First assuming that all angles are 45 or 90o and drawing the hodograph:

From the geometry of the field, AB = BD = FC and AC = BC = CD = DE = (2/2)CF.

From the geometry of the hodograph, V*AB = V*BD = VP, V*AC = V*BC = 2VP, and
V*CD = V*DE = (2/2)VP. The rate of external work will be PkFC VP and this must
equal twice the work rate in the right half of the field.
P FC VP = 2k(V*AB AB + V*AC AC + V*BCBC + V*BDBD + V*CDCD + V*DEDE)
P FC VP = 2k FC VP[11 +22/2 + 22/2 + 11 + (2/2)2/2 + (2/2)2/2]
P/(2k) = (1 + 1 + 1 + 1 +1/2 + 1/2) = 5, P/(2k)= 5
8-4
cos = (L/2)/AO, so AO = BO = DO = L/(2cos)
sin = V1/V*OA, so V*OA = V*OB = V*OC = V*OD = V1/sin
`W = PL.2V1 = 4k(V*OA AO )
Therefore P/(2k) = (1/LV1)(V1/sin)[L/(2cos)] = L/(2sincos)
cos = L/(L2+h2), sin = H/(L2+h2),
so P/(2k) = (L2 + H2)/(2LH) = [H/L + L/H]/2
L/H H/L P/(2k)
1 1 1
2 0.5 1.25
3 0.333 1.667
4 0.25 2.125
5 0.20 2.60
There is agreement with Fig. 8-13 up to H/L = 3 and there would be above this if the figure were
extended.

8-5.

V*OA = V*AB = V*BC = V*CD = Vp/cos45 = 2VP, V*AC = 2Vp

OA = AB = BC = CD= W(22), AC = W/2
Therefore P(W/2)Vp = k{4(2Vp)[W/(22)] + 2Vp(W/2)}
PWVp/2 = WVpk/2(4+2)
P/(2k) = 3 This is > 2.89 so the field in Fig. 8-7 is a better upper bound

8-6. a) Substituting B = cot = 0.08cot10 = 0.4537 and te/to = 0.8 into the Sachs'
equation d/2k = [(1+B)/B][1- 0.8B)] = 0.3085: d = 46.3MPa
The drawing force, Fd = 46.3x106Pa)(0.5x100)x10-6 m2 = 1851N
(with eq 8.39, d/2k = 0.3085 + (1/2)tan10o = 0.397)
Using the law of sines, (Vo=1)/sin30 = V*BC/sin45 = V*AB/sin105
a) V*BC = sin45/sin30 = 1.414; V*AB = sin45/sin105 = 1.9318
V*AC/sin75 = 1/sin40; V*AC = sin75/sin40 = 1.5027
AB = 2/2)/sin40 = BC/sin110 = AC/sin30;
BC = 2sin110/sin40 = 1.4619(2/2)
AC = 2sin30/sin 40 = 0.7779(2/2)
(Vo=1)Pe = k[AB V*AB + BCV*BC + AC V*AB]
Pe.1/(k) = (2/2)(1x1.9318 + 1.4619x1.414 + 0.7779x1.5027)
Pe/(2k) = 1.827
b) VABC = V*AB = 1.932
c) V*AC = 1.503 (from part a)
d) wh = d = 2k = (2k) ln(2), wa = Pe = 1.827(2k)
= wh/wa = Ln2/1.827 = 37.9%

V*BC = Vo = 1; V*AB = V*AC = Vosin90/sin45 = 2 . BC = 1, AC = AB = 0.5/sin45 =

2/2
a) Pe.1.1 = k[(2 )(2/2) + 1.1 + (2 )(2/2)] = 3
Pe/(2k) = 1.5 (this is better field is better than that in prob. 8-7)
b) VABC = V*AB = 1.414
c) V*AC = 1.414
d) wh = d = 2k = (2k) ln(2), wa = Pe = 1.5(2k)
 = wh/wa = Ln2/1.5 = 46.2%

8-9 Since regions DOA and COB move with the loading platens, there is no
relative movement or velocity discontinuity along DA and CB. Therefore the same
answer applies whether the interface is frictionless or there is sticking friction.

8-10 a) L/h 1+(L/h)/4* U.B. (prob 8-4)

1 1.25 1.0
2 1.5 1.25
3 1.75 1.67
4 2 2.125
5 2.25 2.6
* L = b in Eq. 7-25

b) Yes. Eq. 7-25 is the same as Eq. 8-20 which was derived with upper-bound
assumptions. Although the slab analysis predicts lower values for P/2k with L/h > 3.5
than this upper bound, Fig. 8-13 shows that for large L/h, other upper-bound fields
give lower values of P/2k than this solution. The slip line field (chapt. 9) is still lower.

8-11 Refering to the example after Eq. 8-15 where the time increment t was cosen so
t = 1, it was shown that the values of dx associated with P, Q, & R were 1.402, 1.567
& 1.732 respectively and that these numbers indicate that points move to a straight
line P'Q'R'.
Consider a point U midway between P & Q. Initially, do = (1/4)tan15 = 0.067, Vo = 1. t
= 1, d1x = (3/4)(3/2) = 0.649. V1x = 1.183 ( as in text) so dx = 2.1 + 0.067(1-2) +
0.649(1-2/1.183) = 1.485
Consider now point V midway between R & Q, do = (3/4)tan15 = 0.201
d1x = (1/4)3/2 = 0.2165, V1x is still 1.183 so
dx = 2.1 +0.201(1-2) + 0.215(1- 2/1.183) = 1.65. Finally, plotting:
tan = h/w, sin = h/{2[(h/2)2 + (w/2)2]1/2},
cos = w/{2[(h/2)2 + (w/2)2]1/2}
tan = h/t, sin = h/{2[(h/2)2 + (t/2)2]1/2},
cos = t/{2[(h/2)2 + (t/2)2]1/2},
OA = [(h/2)2 + (w/2)2]1/2, AC = t, AG = GC = [(h/2)2 + (t/2)2]1/2
V*OA = Vo/sin = 2Vo[(h/2)2 + (w/2)2]1/2/h see hodograph
V*AG = V*GC = Vo/sin = 2Vo[(h/2)2 + (t/2)2]1/2/h see hodograph
V*AC = V2 + V*AGcos = V*OAcos + V*AG cos = Vo(w/h + t/h)
The work rate in the quadrant is
P(L/2) Vo = k[OAV*OA + 2AGV*AG + ACV*AC]
P/(2k) ={[(h/2)2+ (w/2)2](Vo/h) + [(h/2)2 + (t/2)2](2Vo/h) + (w/h + t/h)Vot}/(LVo)
P/(2k) = (3/2)(h/L) + (w2/2 +2t2 +tw)/(hL)
P/(2k) = (3/2)(h/L) + [2/(hL)][(L2-2Lw + w2)/4 + w((L-w)]P/(2k) = (3/2)(h/L) + L/(2h) +
w2/(2Lh) - w/(2h) which is Eq.(8-24)Now differentiating, 1/(2k)dP/dw = 0+0+w/(hL) -
1/(2h), so at the minimum
w = L/2.
Substituting: P/(2k) = (3/2)(h/L) + L/(2h) + L2/(8hL) - L/(4h)
P/(2k) = (3/2)(h/L) + (3/8)(L/h) which is Eq.(8-25)

8-13

tan = h/w, sin = h/{2[(h/2)2 + (w/2)2]1/2},

cos = w/{2[(h/2)2 + (w/2)2]1/2}
tan = h/t, sin = h/{2[(h/2)2 + (t/2)2]1/2},
cos = t/{2[(h/2)2 + (t/2)2]1/2},
AF = w/2, AB = BC = t, OA = [(h/2)2 + (w/2)2]1/2 = [h2 + w)2]1/2/2
AE = BE = BD = DC = [(h/2)2 + (t/2)2]1/2 = [h2 + t)2]1/2/2
V*OA = V*12 = Vo/sin = (2Vo/h)[(h/2)2 +(w/2)2]1/2 = (Vo/h)[h2 + w2]1/2
V*23 = V*AE = V*BE = V*BD = V*DC = Vo/sin = (Vo/h)(h2 + t2)1/2
V2 = Vo/tan = wVo/h
V*3 = V*AB = V2 + Vo/tan = wVo/h + tVo/h = (Vo/h)(w + t)
V*5 = V*BC = V*3 + 2Vo/tan = wVo/h + 3tVo/h = (Vo/h)(w + 3t)
The work rate in the quarter field is:
P(L/2)Vo = k[OAV*OA + ABV*AB + BC V*BC + 4AE V*AE]
P/(2k) = {[Vo/(2h)](h2+w2) +
(tVo/h)[(w+t) + (w+3t)] + (2Vo/h)(h2+t2)}/(LVo)
P/(2k) = {(h2 +w2)/2 + t[(w + t) + (w + 3t)] + 2 (h2+t2)}/(LVo)
Substituting t = (L-w)/4,
P/(2k) = h/(2L) + w2/(2hL) + [2w/(hL)][(L-w)/4} + [6/(hl)[(l-w)/4]2 + 2h/L
P/(2k) =(5/2)h/L + (3/8)(L/h) - w/(4h) + (3/8)w2/(hL)
Differentiating: [1/(2k)]dP/dw = 0 = -1/(4h) + (6/8)(L/h) or w = L/3 gives the minimum.
Substituting, Pmin/(2k) = (5/2)h/L + L/(3h) which is Eq.(8-26)

8-14 According to eq. 8-43, d = 2k{[o/(2k) + m/sin2] + (2/3)tan};

Substituting o = 20,000 psi, = Ln[1/(1-r)] = Ln[1/.7] = .3567, m = 0.1, and 2k = o
(for Tresca) or 2k = 4/3o (for Mises),
d = 11,570 psi for Tresca and d = 12,256 psi for Mises
Taking = wi/wa and taking wa = d and wi = o = 7,133 psi for both criteria,
= 7,133/11,570 = 0.617 for Tresca (61.7%) and
 = 7,133/12,256 = 0.582 for Mises (58.2%)
8-15

into P.AC .Vup = k(mAC.V*AC + BC.V*BC + AB.V*AB)

P(1.577/2)Vup = kVup[0.1x(1.577/2)((1/3)+(1/3)(2/3)+(1/2)(1/2)]
P(1.577/2)Vup = kVup[1.712],
P/2k = 1.712/1.577 = 1.086
8-17

Pext.6.Vo = k[V*AE. A E + V*AD.AD + V*DB DB + V*BC.BC]

AE = 6/cos22.2 = 6.48, V*AE = Vo/sin22.2 = 2.647Vo

AD = 62tan22.2 = 3.463, V*AD = Vo2/tan22.2 = 3.465 Vo
DB = 2/sin22.2 = 3.743, V*DB = 6Vo/cos22.2 = 6.48Vo
. B C = 2 = 1.414, V*BC = 62Vo = 8.485Vo

Pext.6Vo/k = 17.15 + 12.00 + 24.25 + 12 = 65.4

Pext/2k = 5.45

8-18 a)
c) find largest QIJ = V*IJ IJ ;letting Vo= BD =1:
QAB = QBC = QEF = (1/2)2 = 1; QBD = 1.2 = 2; QDF = 1.1 =1;
QDC = QDE = (1/2)(1.52) = 1.5 Largest energy expenditure is on BD

8-19 a) V* = (z/t/2)VP = (2z/t)VP

b) rate of work on 1/4 of shear discontinuity = kV*dz = k(2z/t)VPdz =
(2kVP/t)(t/2)2/2 = (kVP)(t/2)/2; on all 4 disxcontinuities `W = kVPt
Rate of homogeneous work is `W = (2k)[VP/(t/2)](wt) = 4kVPw
shear work/homogeneous work = kVPt/(kVPw) = (1/4)(t/w)

8-20

Equating with the external work rate, 2PL = 4k(h2 + L2)/2h

or P/(2k) = (1/2)(h2 + L2)/(hL) = (1/2)(h/L + L/h).
Over the whole field, `W int = k(8 A BV*AB + 4 A CV*AC) =

8k(2AB)2 + 4k(L/2)2 = 16k(h2/4 + L2/16)/h + kL2/h = k(4h2 + 2L2)/h.

Equating to the external work rate, 2PL = k(4h2 + 2L2)/h,
P/2k = h/L + (1/2)L/h.

Over the whole field, `W int = k(12 OA V*AO + 4 AC V*AC) =

A12k(2OA2/h +4(2/9)L2/h = 24k(L2/36 +h2/4)/h +(8/9)L2/h = k[(14/9)L2 +6h2]/h.
Equating to the external work rate, 2PL = k[(14/9)L2 +6h2]/h,
P/2k = (3/2)h/L + (7/18)L/h
Note that field I is the lowest for L/h < 3 and Field III for 3 < L/h < 5. Field II and the
slab solution are nowhere the lowest.

CHAPTER 9

9-1 a) 1ED = 0, 2ED = -k = 2C and DCFBA is an -line.

2B = 2C + 2k(CB) = -k +2k(-/2) = -k(1+) = 2AE
3AE = 2AE -k = -2k(1 + /2) = -P,

so P/(2k) = 1 + /2 = 2.57 as in Fig 9-9

c) Intense shear occurs along ABFCD. Note that along BE and EC

deformation is gradual.
Letting AE = 1, AB = 1/2 = BE = CD;
BC = BE (/2).V*AB = Vp/(1/2) = 2Vp = V*BC = V*CD
so the rate of energy dissipation along these lines is
k( AB V*AB + BC V*BC + CD V*CD) or
 k[(1/2)(2)Vp + /(22)(2)Vp + (1/2)(2)Vp] or
(1 + /2 + 1) = 2+/2k = 3.57k.
The total rate of energy dissipation from (a) is 5.14k, so the % of
energy dissipated along these lines is 3.57/5.14 = 69.5%. The rest
of the energy is consumed by gradual deformation inside BEC.

9-2.

DEFG is an -line. Rotating through = - on DEFG,

2G = -k + 2k((-) = -k(1 + 2); In OGO', 3 = 2G -k = -P, so 3 =
-2k(1 + ); P = 2k(1 + ), P/(2k) =1 + = 4.14

2A = -k + 2k(-/6) = -k(1 + /3) = 2BC

3BC = 2BC - k = -P = -2k(1 + /6) so P/2k = 1 + /6 = 1.523
On the other hand, for penetrating deformation, P/2k = 1.15
according to Fig. 9-20, which is lower and therefore appropriate
For von Mises, 2k = 2Y/3 so P = 2.25,000/3 = 33,200 psi

b) From physical considerations, the an exit velocity with a downward

component would seem more reasonable than that predicted by the
hodograph above. With a downward component to the exit velocity a
smaller reduction would be required and therefore probably a lower
extrusion force.
9-5 Substituting 2 = 120o into cos(2 - ) = cos /(1+sin), and
solving by trial and error, = 50.84o = 0.887 radians. Starting on the
left-hand side, at the surface 1 = 0, so P = k. Now rotating on a -line
thru = +0.887, the pressure in the next to indentor is
P = k + 2k(0.887); P = P + k = 2k(1.887). Let the length of
contact between indentor and material be 1, then F = P,
Fx = F sin60 = Psin60, x = Fx/sin60 = P = 2k(1.887), x /2k = 1.887

9-6a) By inspection, A'B'CD is an -line and CD and A'D' are -lines.

Along CD', x = 0 so PCD' = k, rotating on -lines -/2 from CD' to A'D',
PA'D' = PCD' -2k(-/2) = k +2k(/2)
This is the pressure in A'E'D', so Pext = P = PA'D' + k = 2k(1+/2)
pext/2k = 2.57

c) V*AD = V*CD = (2/2)Vo = 2/2 = .707

d) rate of energy expenditure along AD and CD = k(AD V*AD+ CD V*CD) =
2k AD V*AD = 2k(2)(2/2)] = 2k
rate of energy expenditure along arc ABC = k ABC V*ABC
arc length, ABC = 2/2), the velocity discontinuity along this arc
V*ABC = V*AD = (2/2)Vo = 2/2, so rate of energy = k/2 =2k(/4)
total rate of work = PextVox1 = 2k(1+/2)
fraction expended on lines AD, CD & arc ABC = (1+/4)/(1+/2)= 69.4%
rest is expended in fan = (/4)/(1+/2) = 30.6%

9-7 This is one of the special fields covered in sect 9-6 for which
sin = r/[2(1-r)]. (Here = 90o=/2 so sin = 1 and r = 2/3.
For these fields Pext/(2k) = r(1+) = (2/3)(1+ /2) = 1.714
= wi/wa = 2k/Pext = 2k/[2kr(1+)] = Ln3/[(2/3)(1+ /2)] =
= 64.1%
Note this problem can also be solved by realizing that along PCD = k,
and rotating on an -line thru = -/2, PABD = k + 2k(/2)
P = PABD + k = 2k(1+/2), 3Pext = 2P,
so Pext/2k = (2/3)(1+/2) etc.
9-8 1FG = 0, 2FGE = -k, FEDA is an -line.
a) starting from the right side of the field,
2D = 2E + 2kDE = -k + 2k(-R) (clockwise) so 2D = -k -2kR
starting from the left side of the field,
1AB = 0, 2ABC = -k, BCDG is a -line.
2D = 2C - 2kDC = -k - 2k(L) (counterclockwise) so 2D = -k -2kL
Since R > L, the value of 2D calculated from the two fields is
different. The full field cannot be correct.
b) simply use the portion GDCBA which gives the lower value of
P/(2k)

b) VED from slip-line hodograph is 3 = 1.732 = VE

c) VF from upper-bound hodograph is 5 = 2.236= VBCD
d) AD = 2 = BC, BD = 2 so BEC = (2/2) = /2
Along BC, the work rate is k(BC V*BC) = 2.2k = 4k
Along BEC, the work rate is k(BEC V*BEC) = k(/2)(2) = k

9-10 The highest mid-plane tensile stress occurs in the field with the
highest H/L for which deformation penetrates. From fig 9-20, H/L =
 8.75. For this field P/2k = (1 + /2). The value of P in the triangle
below the indentor is P - k. The field corresponds to a centered
fan with = + = 5/12 + (8.75-8.16)/(12.37-8.16)(/12) =
5.13(/12)
At the centerline,
P = P -k -2k(+ ) = (1 + /2)(2k) -k -2k(2x5.13)(/12)
P/2k = (1 + /2) - .5 - (2x5.13)(/12) = -.615, = +.615

9-12 a) The area of shear = 2t, The internal work rate is `W int = k 2tVp.
The external work rate is `W ext= PwVp.
Equating, PwVp = k2tVp, P/(2k) = t/w.
b) Hardness indentation will occur if P/(2k) = 1 + /2 = 2.57. Therefore
since P/(2k) = t/w, if t/w > 2.57, a hardness indentation will occur
instead of punching of the slot.
c) Now the upper-bound gives W int = kdtVp = W ext= P(d2/4)Vp.
Therefore, P/(2k) = 2t/d. Equating with P/(2k) = 3, 2t/d = 3; d/t = 2/3.
NOTE : This is a minimum value of d/t for hole punching, not a maximum as implied by the problem st
9-13 For the slip-line field (a): Along CD 1 = 0, 2 = k, and CBA is an -line
2A = 2ACD = 2C + 2kAC where AC = -/2
2ACD = -k + 2k(-/2) = -k(1 + )
3AD = 2ACD - k = -2k(1 + /2) = - P
P = 2k(1 + /2); Making a force balance, P.1 = 2Pe so Pe = k(1 + /2)
Pe/(2k) = (1 + /2)/2 = 1.285

For the upper-bound field, r = 50%, Ve = 2Vo and =

2PeVo = k(AO V*AO + OC V*OC) = k(2(t/cos)(Vo/cos),

Substituting cos = t/AO and AO2 = t2 +1
2PeVo = 2kVo[t(t2+1)/t2] = 2kVo(t + 1/t), Pe/(2k) = (t + 1/t)/2
t Pe/(2k) t Pe/(2k) t Pe/(2k)
.25 2.125 .75 1.04 2 1.25
.375 1.52 1.0 1.0 3 1.67
.5 1.25 1.25 1.025 4 2.125
.625 1.11 1.5 1.08 5 2.6
 Note the general similarity with Fig. 9-30. Because of the assumption of frictionless
conditions, the result is similar to an indirect extrusion. Also prob. 9-19 addresses the
question of pipe formation

9-14 First label the and -lines as shown. This is easily done at point C, where
obviously the most tensile direction (and therefore the 1 axis)
is vertical.

In triangle ABF, y = 3 = 0. 2(FB) = k. Moving along a line to FC,

2(FC) = 2(FB) - 2k() = k - 2k(-/2)
Every where within region CFIG, 2 is the same and
1 = 2 + k = 2k + 2k(/2) = 2k(1+ /2).
The stress = F/x = 1= 2k(1+ /2), so /2k = (1+ /2) = 2.57
Note that half of this field is exactly the same as the field for plane- strain indentation
except that all of the stresses are tensile here instead of compressive. Our answer for the
stress here is the same as for the indentation problem (1+ /2 = 2.57) except that the
stress is tensile.

9-15 At the surface, the stress normal to the surface, 3 =0, so 2 = k.

Rotating 45o = /4 to the center, 2 = k + 2k(/4). and here 1 = 2 +
k = 2k(1+/4). The stress is the same everywhere along a cut through
the center so x = 1 = 2k(1+/4). x/2k = (1+/4) = 1.785
9-16 From problem 9-15, the value of x necessary to operate the field is
x/2k = 1+/4 = 1.785, or x = = 1.785(2k) = 3.571k.
Alternatively, shear could occur on a 45o plane from the base of the
notch to the opposite surface. The shear stress on such a plane,
= Fxcos45/{(1/cos45)(tn +to)/2} = = (1/2)xtn /[(tn +to)/2]
= xtn /(tn + to).
Shear will occur on such a plane when = k, so for shear
k = xtn/(tn + to) or x = k(tn + to)/tn = k(1+ to/tn)
For the field to operate instead of shear, 3.571k < k(1+ to/tn), or
to/tn > 2.571

9-17a) An x-direction force balance gives Pext.1 = P(r/sin15)sin15 = Pr.

If for = 15 and r = 0.076, pext = 2k(0.178),
P = 2k(0.178/( 0.076) = 2.342(2k)
Then P in ABO,O = P- k = ( 2.342 -.5)(2k) = 1.842(2k)
Rotating by = + 5/12 and = -4 /12 to the centerline,
P4,5 = 1.842(2k) - (2k)(9/12) = -0.514(2k) or 2 = +0.514(2k)
(b) If this were a drawing operation the drawing stress would be
d/2k = 2k(0.178) and an x-direction force balance gives
d(1-r) = Pr, so
P= d(1-r)/r = 2k(0.178)(1- .070)/.076 = 2.164(2k).
Now P in ABO,O = 1.646(2k) and moving to the centerline,
P = 1.646(2k) - (2k)(9/12) = -0.710(2k) or 2 = 0.710(2k).
(c) The higher hydrostatic tension at centerline in drawing would cause
more centerline porosity and internal cracks, lowering the toughness.

9-18 For an octagon the value of h/L = 1 + 22/2 = 1 + 2 = 2.414.

For penetrating flow with h/L = 2.4, figure 9-20 indicates that
P/(2k) = about 1.4.
The non-penetrating flow field is very similar to the hardness
indentation except that the centered fans are now /4 instead of /2,
Consequently the pressure required is P/(2k) = 1 + /4 = 1.785.
Since this is higher than the pressure for penetrating flow, we should
expect penetrating flow (right-hand figure).

9-19 The following analysis is based on simplifying assumptions that are

not correct. Yet the results do indicate the basic reason for pipe
formation in extrusion. These assumptions are:
1. 2Pe is the force applied to the piston. (It should be 2Pe(1-2x) but
 this leads to messy math.
2. What is called Pe is the average value of the extrusion pressure,
which is not uniform.
As point C moves upward along the piston face, x increases, and the
metal adjacent to the piston face moves faster than Vo so a pipe
forms. A general hodograph is shown:

Now Ve depends on x, Ve(1-x) = Vo(2-x) or Ve = (2-x)/(1-x)

Now to find the value of x for a minimum Pe.
2VoPe = k[AOV*AO + COV*CO]; V*AO = Vo/cos and V*CO = (Ve -Vo)/cos,
AO = t/cos, CO = t/cos
Now, V*CO = [(2-x)/(1-x) -1]/cos = 1/[(1-x) cos]
2VoPe = k{(t2+1)/t + [t2 + (1-x)2]/[t(1-x)]} (a)
Setting dPe/dx = 0 to find the minimum, t/(1-x2) -1/t = 0 or t = 1-x,
so when = 45, Pe is a minimum. Substituting t = 1-x into (a),
Pe/(2k) = (1/4)[1-x + 1/(1-x) + 1 +1] = (1/4)[3 - x + 1/(1-x)]
Pe/(2k) = (1/4)[2+t+1/t]
(note this solution is valid only for t 1 ( 45 an x 0. For t 1 the solution of Prob.
9-13 gives a lower value than the slip-line field solution)
t Pe/(2k) t Pe/(2k)
.25 1.56 .625 1.056
.375 1.26 .75 1.02
.50 1.13 1.00 1.00

9-20 Refer to Figs. 9-19 and 9-21.

 Take a cut from A through 0,2, and 1,3 to 2,4 and make an x-direction
force balance. This cut is easy to analyze because everywhere along it the
and lines are at 45 to x, so x = 1 and the net force is Fx = xdy = 0.
Using figure 9-19 and letting x and y in that figure be x' and y',
Point x' y' y = y'cos30 + (x'-1)sin30
A 1.0 0.0 0.0
0,2 0.638 1.366 1.00 1,3
0.904 2.12 1.788 2,4 1.335
3.195 2.935
a) hf = 2.935, ho = hf +2sin30 = 3.935
The reduction , r = (ho -hf)/ho = 0.254 or 25.4%
b) A force balance on the die walls is

PAB = P0,0 = -3(0,0) and 3(0,0) = 2(0,0) - k

so at point 0,0, 2 = 3 + k = -3.935Pe + k
2(0,2) = 2(0,0) +2k = -3.935Pe + k + 2k/6 ( = +/6)
Now rotating from 0,2 to 0,3 by = +/12 and then from 0,3 to 1,3
by = -/12
2(0,2) = 2(0,0) +2k = -3.935Pe + k + 2k/6
2(1,3) = 2(0,2) +2k(/12) - 2k(-/12) = -3.935Pe + k[1+(2/3)]
Now rotating from 1,3 to 1,4 by = +/12 and then from 1,4 to 2,4
by = -/12
2(2,4) = 2(1,3) +2k(/12) - 2k(-/12) = -3.935Pe + k([1+)
Everywhere along the cut x = 1 = 2 + k
from A to 0,2 (y from 0 to 1), 1 = -3.935Pe + 2k(1 + /63)
at 1,3 (y = 1.788), 1 = -3.935Pe + 2k(1 + /3)
at 2,4 (y = 2.935), 1 = -3.935Pe + 2k(1 + /2)
Noting that for all these points, x = -3.935Pe + 2k + f(y),
Fx = 0 = xdy may be expressed as
Fx = 0 = (-3.935Pe + 2k)(2.935) +f(y)dy. Now plotting f(y) vs. y:
 It can be seen that f(y)dy =
1.k/3 + (1.5k/3)(1.788 -1.00) + (2.5k/3)(2.935 -1.788) = 5.29k
Fx = 0 = -3.935Pe(2.935) + 2k(2.935) + 5.29k
Pe/(2k) = 0.483
c) = wi/wa where wi = 2kh = 2k( ln[1/(1-r)] = 0.293 and wa = Pe
= 0.293/0.483 = 60.7%
d) at point 2,4, 2 = -3.935Pe + (1+)k = -3.935(.483.2k) + (1+)k
2/(2k) = +0.170 Note that this is tensile!

c) m = /k = sin 30 = 0.500

CHAPTER 10

10-1 h/Rrho = 4/6(0.5)(4) = 3.6 which is much larger than 1. To avoid center-line
cracking, should be lowered. Therefore increase the reduction per pass as suggested by the
foreman. (Front and back tension are impractical on a 15 inch long billet in a 12 in. diameter
mill and if possible it would only raise the level of hydrostatic tension at the center- line.) Note
using Eq (10-5) gives = 3.56.
10-2 With a very small potential reduction, the contact length between the rolls and bar is
very small, so is large. Therefore, there is hydrostatic tension at the center, making the
required piercing force quite small. The mandrel tends to stay at the center where the
hydrostatic tension is greatest, and therefore the required piercing force the least.

10-3 a) For plane strain, Eq. (10-11a) gives f = 1 + (1/2)tan/h, and Eq. (10-3) gives = (2/r
-1)sin.
Substituting r = 1 - exp(-h) - 1 -[1 - h + h2/2 - h3/3! - ....],
r h for small h and sin tan for small .
(2/h -1)tan, or 1/h = 1/2 + /(2tan).
Substituting into Eq. (10-11a),
1 + (1/4)(tan + ) but tan << for small , so
1 + /4
For axisymmetry, Eq.(10-11b) gives = 1 + (2/3)tan/h and Eq. (10-4) gives = (sin/r)(1 +
1-r)2 4 sin/r 4sin/h for small r. Substituting 1/h /(4sin) into Eq. (10-11b) and
letting sin tan,
= 1 + /6
b) For plane strain:
= 1 + (1/2)tan30/ ln[1/(1-0.5)]= 1.416
= 1 + (1/4)(2/.5 -1)sin30 = 1.375
the error is (1.416- 1.375)/1.416 = 2.9%
For axisymmetry:
= 1 + (2/3)tan30/ ln[1/(1-0.5)]= 1.556
= 1 + (1/6)(sin30/0.5)(1 - 1-0.5)2 = 1.486
the error is ( 1.556 - 1.486)/ 1.556 = 4.5%
At lower reductions the error is much less

10-4 a) The mean crossectional area is Am = (Ao + Af)/2 and

r = (Ao - Af)/Ao so Af = Ao(1-r).
The contact area is Ac = (Ro + Rf)[(Ro + Rf)2/tan2 + (Ro - Rf)2]1/2
Ac = (Ro + Rf)(Ro - Rf){1/tan2 + 1]1/2 =
Ac = (Ro2 -Rf2)[cos2/sin2 +1]1/2= (Ao-Af)[(cos2+sin2)/sin2]1/2Ac = (Ao-
Af)/sin = Aor/sin.
The ratio Ac/Am = [(Ao-Af)/sin ].2/[Ao(2-r)] = 2r/[(2-r)sin = 2(0.25)/[(2-0.25)sin 6] = 2.733
b) = (sin6/0.25)(1+1-.25)2 = 1.46
d) Eq. (10-3) gives = (2-r)sin/r = 1.46 so 1.46r = (2-r)(.1045);
r = 0.134
d) Using Eq (10-6),
Ac/Am = 2r/[(2-r)sin] = 2(.134)/[(1.866)(.1045)] = 1.374
e) For the same and , there is much greater contact area with axisymmetric drawing
and since the stress acting normal to the work-die interface is about the same, the normal
force and thus the frictional force is much greater.

10-5 a) Let L be the distance from the apex to the arc as shown.

sin = (Ro + Rf)/(2L) or L = (Ro + Rf)/(2sin)

The arc length = 2L = (Ro + Rf)/(2sin)
The contact length is (Ro + Rf)/sin so
= arclength/contact length = (Ro + Rf)sin/[sin (Ro - Rf)] =
= (Ro + Rf)/(Ro - Rf)
r = (Ro2 - Rf2)/(Ro2) = 1 - (Rf/Ro)2; Rf = Ro(1-r)
= (1 + (1-r) )/(1 - (1-r) ) = (/r)(1 + (1-r))2.

b) = (1+(1-r))2 = sin(1(1-r))2 % difference

=10, r=0.25 2.431 2.419 0.5
=10, r=0.50 1.017 1.012 0.5
=45, r=0.50 4.577 4.121 10.
=90, r=0.25 9.155 5.828 36.3

10-6 Substituting = 0.05, C = 0.12 and r = 0.3 and

= (1 + (1-r) )2sin/r =(1 + (1-.3))2sin/.3 = 11.244sin into
= [1 + C(-1) + /tan]-1;
= [1 + 0.12(11.244sin -1) + 0.05/tan]-1
= [0.88 +1.349sin + 0.05/tan]-1.
Now substituting = 2,4,6,8,10,12,14 and 16
For = 2, = 0.424; for = 4, = 0.592; for = 6, = 0.668; for = 8,
= 0.7024; for = 10, = 0.7153; for = 12, = 0.7164;
for = 14, = 0.7107; for = 16, = 0.7011.
Trial and error gives * = 11.2, * = 0.717. Plotting:
b) d(1/)/d = 0.12[(1+(1-r) )2cos/r] - csc2 = 0.
cossin2 = r/[0.12 (1+(1-r))2].
Substituting r = 0.3, = 11.2 as found in part a.
As icreases, * increases. As r increases, * increases.

10-7

To the first approximation, the deformation will be in plane strain. The slip-line field has
dead metal caps along the platens and wedges of undeforming material at the ends. These
should be regions of low hardness. The high hardness region is expected in the active regions of
the slip-line field

10-8 Use as low a as possible to avoid center-line bursts, i.e. a low die angle (8) and as
high a reduction as possible without drawing failure. Neglecting work hardening, the highest strain
(reduction) per pass is
max = = 0.5
The total strain needed is 2 ln(1/.65) = 0.86 so two passes are required. Therefore choose
schedule B.

CHAPTER 11

11-1 a) The higher stresses necessary for forming are more likely to cause fracture. The
toughness generally decreases as the stress level rises.
b) Without shape control, the inclusions are elongated in the rolling direction. In a
transverse direction test they form a much larger area perpendicular to the tensile axis and
therefore an easy fracture path.With shape control they tend to be spherical so the area
perpendicular to the tensile axis in a transverse direction test is much less.

11-3 a) The highly elongated silicates inclusions formed easy fracture paths for cracks
parallel to the rolling direction.
b) The insoluble silicate inclusions tended to block the corrosion, requiring corrosion to
follow a more tortuous path.

11-4 The 6061-T6 aluminum had previously been processed, probably by rolling, and
undoubtedly had some microporosity already present. The increased density occurred by
closing of the existing porosity.

11-5 a) There is a higher hydrostatic tension in drawing.

b) The stress state in rolling is compressive, so porosity doesn't grow as in tension.

11-6 If friction were absent, both the inner and outer diameters would increase by the
same percentage. This is because the deformation would be homogeneous, with the hoop
strain being the same on both the inner and outer sides of ring.
However this requires sliding of the whole ring surface outward. With friction the
center of the ring would tend to remain fixed in place, requiring the inner diameter to decrease
while the outer diameter increases. Thus the ratio of (DID/DID)/(DOD/DOD) will decrease
from 1 to nearly -1 as the friction increases.

11-7a)

b) higher friction and a lower ho/do ratio would promote a greater ratio of 1/|2| by causing
earlier barreling.

CHAPTER 12
12-2 a) Assuming the Mises criterion, x = 1.15Y (plane strain), but
2
x = Eex/(1- ) and ex = t/(2R) = t/D
1.15Y = (Et/D)/(1-2), D = 30x106x0.035)/(1.15x40,000x0.91) = 25 in.
b) Again, x = 1.15Y and x = Eex/(1-2). The stored elastic energy per volume, w,
is w = (1/2)xex = E'ex2 where E' = E/(1-2).
ex varies with position, ex = z/R = 2z/D, where z is the distance from the neutral plane.
Taking L as the length coiled, b as the width and t the thickness, the total elastic
energy, W, is
W = 2Lb wdz = 2(1/2)E'exLb (2z/D)2dz where the integration is between z =0 (mid
plane) and z = t/2. (The factor 2 is to account for the material between z = -t/2 and z =
0).
Integrating, W = 4LbE'(t/2)3/(3D2) = LbE't3/(6D2)
The work rate is `W = Wv where v is the velocity = L/t', where t' is the time to roll a
length L.
Substituting, W =v LbE't3/(6D2) = 100.80.30x106(0.035)3/([0.91.6.252) = 3,015 ft.lb/s or
3015/550 = 5.5 HP.
12-3.

a) For beam, = C FL3/(bt3), where is the deflection, F is the applied force, L is the span, b the
width, t the thickness, E the modulus, and C a constant that depends on the end conditions,
load distribution, etc. However for constant F, , b, and L, Et3 = constant, so EAltAl3 = Esttst3,
wtAl/wtst = (Al/st )(tAl/tst) = (Al/st )(Est/EAl)1/3 = (2.7/7.9)(30x106/10x106) = 0.493
Weight saving = (1-0.493) = 50.7%
b) If the panel were curved, the potential weight saving would be much less than in a). For the
flat sheet, the additional material is at the extreme position relative to the neutral plane, where it
is most effective in stiffening the panel. With a curved panel, however, much of the additional
 material would be nearer the neutral plane, where it is much less effective. Therefore the %
increase to achieve the same thickness would be much larger and the weight saving less.

12-4
The energy absorbed is U = Fd but d = [AL3/(E'wt3)]dF, where is the deflection, L is the
span, t is the thickness, w is the width, E' = E/(1-2) is the plane-strain modulus, F is the force,
and A is a constant that depends on the load distribution and the support. Integrating,
U = [AL3/(E'wt3)]FdF = AL3F2/(2E'wt3)
For constant U, A, L, and w, F2/(E't3) must also be constant. Therefore, assuming that is the
same for steel and aluminum,
FAl2/(EAltAl3) = Fst2/(Esttst3). (a)
But the force is limited by yielding. Up to ant at yielding, the stress at the surface is given by =
Mc/I where the bending moment, c = t/2 and I = wt3/12 so = 6M/(wt2) or M = wt2/6.
Realizing that at yielding = Y, and F is proportional to M, F is proportional to Yt2. Substituing
in a,
(YAl2tAl4)/(EAltAl3) = (Yst2tst4)/(Esttst3);
(tAl/tst) = (EAl/Est)(Yst/YAl)2
The weight, W, is proportional to the thickness, t, times the density, , so
(W Al/W st) = (Al/st)(tAl/tst) = (Al/st)(EAl/Est)(Yst/YAl) =
(2.7/7.9)(10/30)(35/25) = 0.223
Wt. savings = (1-0.223) = 77.6%

12-5 a) ex = z/R, x = C1 + C2ex (assuming Tresca). Assuming w = 1,

t/2 t/2
M = 2 o xzdz = 2 o (C1 + C2z/R )zdz
M = 2[(C1/2)(t/2)2 + (C2/3)(1/R)(t/2)3]
On unbending, x = E'ex, and ex = z (1/R)
M = 2o xzdz = 2 o E'(1/R)z2dz = (2E'/3)'(1/R)(t/2)3
t/2 t/2

M + M =0, so 2[(C1/2)(t/2)2 + (C2/3)(1/R)(t/2)3] + (2E'/3)'(1/R)(t/2)3 = 0

(1/R) = -[3C1 + C2(1/R)t]E't.
Since ex + ex = e'x, (1/R) + (1/R) = (1/R') = 1/3; (1/R) = 1/3 - (1/R)
1/3 - (1/R) = -[3C1 + C2(1/R)t]E't
(1/R)(1-C2/E') = 1/3 + 3C1/(E't)
1/R = [1/3 + 3C1/(E't)]/(1-C2/E') =
= (1/3 +3x25x103/(11x106x 0.04)]/[1 -25x103/11x106) = 0.505, R =1.98in.
b) ex = z/R + 0.02, x = C1 + C2ex. Now x varies continuously across the section
so, integrating from z = -t/2 to + t/2,
M = [C1 + C2(z/R + 0.02]zdz = [C1 + 0.02C2)zdz + C2(1/R)z2dz =
(1/2)(C1 + 0.02C2)[(t/2)2 -(-t/2)2] + (1/3)C2(1/R)[(t/2)3 -(-t/2)3] = (2/3)C2(1/R)(t/3)3
As in a) above, M = 2E'(1/R)(t/2)/3 and M + M = 0, so
-C2(1/R) = E'(1/R). Again '(1/R) = 1/3 - 1/R or -C2(1/R) = E'(1/3 - 1/R)
-(C2 + E')(1/R) = E'/3; 1/R = (E'/3)/E' - C2 = (11x106/3)/(11x106 - 25x103)
1/R = 1.002/3 = 2.993 in.
[Note that tension has almost eliminated the springback]

12-6 At yielding, x = E'ex and x = C1 + C2ex so

ex = C1/(E' - C2) = 25x103/(11x106 - 25x103) = 2.278x10-3
ex = z/R, so at the elastic-plastic in terface, z = Rex = 1.98x2.278x10-3 = 4.51x10-3 in.
Fraction elastic = 4.51x10-3/0.02 = 22.6%
t/2
12-7 M = 2o xzdz, (assuming w = 1) and x = E'ex = E'z(1/R) so M
= 2 o E'z(1/R)zdz = -2E'(1/R)(t/2)3/3
t/2

t/2
but also M = 2 o xzdz
Case A: x = 's (a constant where s refers to the surface). Then
M = 2's(t/2)2/2 = 's(t/2)2 Equating,
's(t/2)2 = -2E'(1/R)(t/2)3/3; 's = -(2/3)E'(1/R)(t/2)
With do = 1, d = 1.005, Ro = 1/2 and R = 1.005/2
(1/R) = 1/R - 1/Ro = -9.95x10-3, E' = 16x106/(1-0.32); t/2 = 0.1 so
's = -(2/3)(16x106/0.91)(-9.95x10-3)(0.01) = 1166 psi
Case B: x = [z/(t/2)] 's so M = 2 ['s/(t/2)] z2dz = (2/3)['s/(t/2)](t/2)3 = (2/3)'s(t/2)2
t/2

Equating, (2/3)'s(t/2)2 = -(2/3)E'(1/R)(t/2)

's = - E'(1/R)(t/2) = (-16x106/0.91)(-9.95x10-3)(0.01) = 1750 psi

12-8 The shear force on an annular element of thickness, dr, at a distance, r, from the
axis is .2rdr where is the shear stress. The torque, dT, on this element is dT =
.2r2dr. On plastic loading, = k so integrating between r = 0 and R, 2kr2dr =
(2/3)kR3. On elastic unloading,
T = 2r2dr, but now t = G and since = r/L, = r/L so
= G r/L. T = 2(G/L)r3dr = (/2)GR4/L.

For equilibrium, T + T = 0 so (2/3)kR3 = -(/2)GR4/L

b) R/L = -(4/3)k/GR
a) The residual stress, ' = + = k + but
 = G = Gr/L and /L = -(4/3)k/(GR) so ' = k[1- (4/3)(r/R)]
(At the surface where r = R, 's = -k/3)

12-9. The strip will continue to unbend so R" > R' > R. After unloading, the strip
undergoes some springback (R' > R) and the outside surface is under compression and
the inside tension. Removing these layers will cause an unbalance of the bending
moment that can be corrected only if the strip further unbends (R" > R') causing the
ouside compression in the new outside surface and tension in the new inside surface.

CHAPTER 13

13-1 Let the tensile axis be x'. Then x = x'cos2, y = x'sin2 and
xy = x'cossin. Using the flow rules, Eq.(13-7),
x = [H(x -y) + G(x -z)] = [H(cos2 -sin2) +Gcos2]x'
y = [F(y -z) + H(y -x)] = [Fsin2 +H(cos2 -sin2)]x'
xy = 2xy = 2Nxy = 2Ncossinx'
z = [F(z -y) + G(z -x)] = -(Fsin2 + Gcos2)x' but
y' = xsin2 + ycos2 - xycossin so
R = y'/z = (xsin2 + ycos2 - xycossin)/z =
R = {[H(cos2 -sin2) +Gcos2]sin2 + [Fsin2 +H(cos2 -sin2)]cos2 -
2Ncos2sin2}/[-(Fsin2 + Gcos2)] =
R = [H(cos4+sin4 -2cos2sin2) +(2N-F-G)cos2sin2]/(Fsin2 + Gcos2) Since 1 =
(cos2 + sin2)2 = cos4 + 2cos2sin2 + sin4, we can substitute cos4 + sin4 = 1 -
2cos2sin2,
Therefore, R = [H + (2N - F -G -4H)cos2sin2]/(Fsin2 + Gcos2)

13-2a) for = 45, cos2 = sin2 = 1/2, so from prob 13-1,

R45 = [H +(2N-F-G-4H)/4]/[(F+G)/2] = (2N-F-G)/[2(F+G)]
R45 = (2N/G -F/G - 1)/[2(F/G+1)]; 2N/G = 2(F/G+1)R45 + F/G +1.
Now substitute F/G = R/P; 2N/G = 2(R/P+1) R45 + R/P +1 or
N/G =[2(R+P)R45 +R + P]/(2P) = (2R45+1)(R+P)/(2P)
b) Substituting R = 4, P = 2 and R45 = 2.5, N/G =[6x6]/(2x2) = 9
G + H = 1/X2 = 1/(71.5 ksi)2 = 1.96x10-4, H/G = R = 4
5G = 1.96x10-4, G = 0.392x10-4 and H = 4G = 1.568x10-4;
F + H = 1/Y2 = 1/(65.3x103)2 = 2.35x10-10, H/F = P = 2, H = 2F
3F = 2.35x10-4, F = 0.783 and H = 2F=1.567x10-4
N = 9G = 3.521x104.
In a tension test along x', (with x' oriented at from x),
x = x'cos2, y = x'sin2, xy = x'cossin, z = 0. The yield criterion (eq13-3)
reduces to
Fsin4 + Gcos4 + H(cos2 - sin2)2 + 2Ncos2sin2 =1/x'2,
(F + H)sin4 + (G + H)cos4 + 2(N-H)cos2sin2 =1/x'2, Substituting N,F,G & H,
x' =[2.35sin4 + 1.96cos4 + 3.91cos2sin2]-1/2 x104

13-3 From 13-2b, (1/YS)2=(F+H)sin4 + (G+H)cos4 +2(N-H)cos2sin2,

At a maximum or minimum, d(1/YS)2/d = 0
4(F+H)sin3cos - 4(G+H)cos3sin + 2(N-H)(cos3sin sin3cos) = 0.
The solutions sin = 0 and cos = 0 correspond to maxima or minima at 0 and 90. For
intermediate solutions,
(F+H)sin2 - 4(G+H)cos2 + 2(N-H)(cos2 sin2) = 0, or
(F +2H -N)sin2 = (G +2H -N)cos2; tan2 = (G +2H -N)/(F +2H -N),
tan = [(G +2H -N)/(F +2H -N)]1/2. There are intermediate solutions only if (G +2H -
N)/(F +2H -N) is positive.

13-4 a) The stress state in a thin-wall capped tube is x = y/2, z = 0, where x, y

and z are the axial, hoop and radial directions respectively.
Substituting in the Hill yield criterion,
Ry2 + P(y/2)2 + RP(y/2)2 = P(R+1)X2,
y2= X2P(R+1)/(R + P/4 +RP/4), Substituting R = 2.5, P = 0.8 and X = 105,
y2= 0.875X2, y = .935x105 psi at yielding.
The pressure P = x(t/r) = .935x105(0.025/2.5) = 935 psi
b) From the flow rules, (eq. 13-12)
x/y = [R(x- y) + (x- z)]/[(R/P)(y- z) +R(y- x)]
Substituting x = y/2, z = 0,
x/y = [R/2 +1]/[(R/P) +R(y- x)] = (1-R)/(2R/P +R). Since R > 1, the axial strain is
negative (the tube shortens. x/y = (1-2.5)/(2x2.5/.8 +2.5) = -0.171
c) Taking the volume inside the tube as v = r2L, dv = (r2dL + 2Lrdr)
dv/v = dL/L + 2dr/r = dx + 2dy.
Substituting dy = 1/(-.171)dx = -5.8dx (from part b),
dv/v = -4.8dx . In tension dx is positive so dv/v is negative, and the volume decreases.
d) For the volume to remain constant (dv/v = 0), dy = -(1/2)dx. But according to the
flow rules Eq. (13-12) with z = 0
dy/dx = [(R/P)y +R(y- x)]/[R(x- y) + x]. Substituting = y/x and dy = -
(1/2)dx; -(1/2)[R(1- ) +1] = [(R/P) +R( -1)]
(R/P +R -R/2) = R -R/2 -1/2; = (R-1)/(2R/P+R) = P(R-1)/[R(2+P)]
= y/x = 0.8(1.5)/[2.5(2.8)] = 0.171
Substituting Iinto the yield criterion, Eq (13-11)
[2.5(0.171)2 +0.8 +2.5x0.8(1-.171)2]x2 = 0.8X2,
x = 1.116X = 111,600 psi

13-5 a) From the flow rules, Eq. 13-14) with z = 0,

= y/x = [(R + 1)y -Rx]/[(R + 1)x - Ry] = [(R + 1) -R]/[(R + 1) - R]
b) Using Eq.(13-16) to define effective stress,
= x2[1 -2R/(R + 1) + 2] or = x[1 -2R/(R + 1) + 2]1/2 (Note that for uniaxial

tension, = 0 so reduces to x)

c) d = xdx + ydy + zdz. Substituting z = 0, dy = dx, and

y = x, d = xdx(1 + ), or d = dx(x/ )(1 + )

From part a), + 1 = {[(R + 1) -R]/[(R + 1) - R]} + 1 =

+ 1 = [(R + 1) - 2R + (R + 1)2]/[(R + 1) - R]
From part b), /x = [1 -2R/(R + 1) + 2]1/2,

d = dx(x/ )(1 + )

= dx [(R + 1) - 2R + (R + 1)2]/[(R + 1) - R]/ [1 -2aR/(R + 1) + 2]1/2

(Note that for uniaxial tension ( = 0), this reduces to d = dx)

13-6 a) Using the flow rules, Eq. (13-12) with z = 0 and dy = 0,

dy = 0 = (R/P)y + R(y - x); (R + R/P)y = Rx,
= y/x =R/(R + R/P) = P/(P + 1)
b) Substituting z = 0 and y = xP/(P + 1) into the yield criterion, Eq. (13-11),
x2{RP2/(P + 1)2 + P + RP[1-P/(P + 1)]2} = P(R + 1)X2
x2[RP2 + P(P + 1)2 + P + RP]/(P + 1)2 = P(R + 1)X2
x2[P(R + P + 1)]/(P + 1) = P(R + 1)X2
x = X[(R + 1)(P + 1)/ (R + P + 1)]1/2
c) x = X[(3)(2.5)/4.5]1/2 = 1.291X = 38,700 psi
= 1.5/2.5 = 0.6
d) From eq. 13-10 Y/X = {[P(R+1)(P+R)]/[R(P+1)(P+R)]}1/2 = {[P(R+1)/[R(P+1)}1/2 =
{[1.5(2+1)]/[2(1.5+1)]}1/2 = 0.948, Y = 9.48x 30,000psi = 28,460 psi
13-7 a) Consider a uniaxial tension test in the y-direction. x = z = 0, and y = Y
at yielding. Substituting into the yield criterion, Eq.(13-11),
R(y -z)2 + P(z -x)2 + RP(x -y)2 = P(R + 1)X2,
RY2 + P(0)2 + RPY2 = P(R + 1)X2,
(Y/X)2 = [P(R+1)]/[R(P+1)] or Y = X [P(R+1)]/[R(P+1)]1/2. Substituting
X = 50 ksi, R= 1.6 and P = 2.0, Y = 50[(2x2.6)/(1.6x3)]1/2 = 52.0 ksi.
b) For plane-strain tension, y = 0, with z = 0, the flow rules,
Eq. (13-12), give 0 = (R/P)y + R(y - x),
0 = y(1 + P) - Px, y = [P/(P+1)]x = (2/3)x
Now substituting this, R = 1.6, P = 2 and z = 0 into Eq. (13-12),
[1.6(2/3)2 + 2 + 3.2(1/3)2]x2 = 2x2.6X2
x = X[2x2.6/3.06666]1/2 = 65.1 ksi.
c) If z = 0 and z = 0, the flow rule,(eq 13-12), gives
-(R/P)y - x = 0, or y = -(P/R)x = -(2/1.6)x = -1.25x.
Substituting this, R = 1.6 and P = 2 into the yield criterion,(eq.13-11),
R(y -z)2 + P(z -x)2 + RP(x -y)2 = P(R + 1)X2
[1.6(1.25)2 + 2 + 3.2(2.25)2](x/X)2 = 2(2.6),
(x/X)2 = 0.251,
x = 50x(0.251)1/2 = 25.06 ksi, y= -1.25x = -31.3 ksi
d) With x = y and z = 0, the flow rules, Eq (13-12), give
R(x -y) + x = (R/P)y + R(y -x), y = x[P(2R+1)]/[R(2P+1)] = x[(2x4.2)/(1.6x5)
= 1.05x.
Substituting this, R=1.6 and P = 2 into the yield criterion,
R(y -z)2 + P(z -x)2 + RP(x -y)2 = P(R + 1)X2
{1.6(1.05)2 + 2 + 3.2(.05)2}(x/X)2 = 5.2
x/X = [1.379]1/2, x = 58.7 ksi, y= 1.05x = 61.6 ksi

13-8 a) Using the Hill theory, Eq. (13-14),

(R+1)y - Rx = 0, y = Rx/(R+1),
= y/x = R/(R + 1). For R = 0.5, = 0.5/(1 + 0.5) = 0.333.
With eq 13-19 and a = 6,
y5 = R(x - y)5; y = R1/5(x - y); y(1+R1/5) = xR1/5.
= y/x = R1/5/(1+R1/5).
For R = 0.5, = .51/5/(1+.51/5) = 0.465.

b) Using the Hill theory, = y/x = R/(R + 1). For R = 2,

= y/x =2/(1 + 2) = 0.667.
With Eq. (13-19) and a = 6, = y/x = R1/5/(1+R1/5).
For R = 2, = 21/5/(1+21/5) = 0.535.
(Note that the value of for plane strain is strongly dependent on R according to the Hill
theory, but only slightly dependent on R according to Eq. (13-19) with a = 6.)

13-9 For biaxial tension (y = x or y = x) the yield criterion, Eq. (13-18) becomes
x/X = [(R+1)/2]1/a.
For plane-strain (y = 0), the flow rule Eq. (13-19) predicts
|y|a-1 - R(x - y)a-1 = 0.
When a is an even integer, the absolute magnitude signs are not required, so =
y/x = R1/(a-1)/(1 + R1/(a-1)). The yield criterion, Eq. (13-18)
can be expressed as: xa[1 + a + R(1-)a] = (R+1)Xa
so x/X = {(R+1)/[1 + a + R(1-)a]}1/a
The ratio, , or , can be written as = {2/[1 + a + R(1-)a]}1/a
where = y/x = R1/(a-1)/[1 + R1/(a-1)]
Substituting various values and plotting:

Conclusion; depends strongly on R for a = 2. For exponents of 6 or 8, the is almost

independent of R.

13-10 Let 2/1 be designated by . Then 3/1= -(1+ ).

For -1/2 0, |i|max = 1, and for 0 1, |i|max = |3|.
a) For von Mises = [(2/3)(12 + 22 + 32)]1/2 =

 /1 = {(2/3)[(1 + 2 + (1+ )2]}1/2 = [(4/3)(1 + + 2)]1/2 so
for -1/2 0, /|i|max = [(4/3)(1 + + 2)]1/2 and

for 0 1, /|i|max = [(4/3)(1 + + 2)]1/2/(1+ ).

b) To avoid excessive algebra, calculate /x = (x/ )(1 + )

using the flow rules, Eq.(13-12) with z = 0,

= [y + R(y - x)]/[R(x - y) + x] = [(R +1) - R]/[R +1 - R] =
= [2.8 - 1.8]/[2.8 - 1.8]. Since = X, Eq. (13-16) can be expressed as

x/ = [1 + 2 -2R/(R + 1)]-1/2 = (1 - 1.287 + 2)-1/2. Combining, /x can be found

as a function of by substituting various values of into

= [2.8 - 1.8]/[2.8 - 1.8] and
/x = (1 - 1.287 + 2)-1/2(1 + ).
For 0, |i|max = x, and for 0, |i|max = |z| = (1+)x. To explore the range -1/2
1, (R-1)/(R + 2) 1, or 0.210 1
c) Use the same procedure for the new criterion. The flow rules, Eq. (13-26) can be
expressed as = [7 - R(1-)7]/[1 + R(1-)7] =
= [7 - 1.8(1-)7]/[1 + 1.8(1-)7]
and the yield criterion, Eq. (13-25) can be expressed as
x/ = {(R + 1)/[1 + a8 + R(1-a)8]}1/8 = {2.8/[1 + a8 + 1.8(1-a)8]}1/8

/x = {2.8/[1 + a8 + 1.8(1-a)8]}1/8(1 + ).
The numerical calculations and graph below were done on Microsoft Excel

13-11 a) Using the flow rules, Eq.(13-12) for 1948 Hill with z = 0,
y/x = 1.035 = [(R/P)y + R(y - x)]/[R(x - y)+ x]
1.035 = [(.55/.89)y + 0.55(y - x)]/[0.55(x - y)+ x]
1.035 = [(.618+ 0.55)y - 0.55x)]/[1.55x - y]
1.035[1.55x - y] = [(.618+ 0.55)y - 0.55x)]
(1.035x1.55 + 0.55)x = (.618+ 0.55 + 1.035)y
y/x = (2.203)/(3.3135) = 1.423
Using the flow rules, Eq.(13-24) for the new criterion with z = 0 and a =8
y/x = 1.035 = (R/P)[7 -P(1-)7]/[1 -R(1-)7]
1.035 = 0.618[7 -0.89(1-)7]/[1 -0.55(1-)7]
[7 -0.89(1-)7]/[1 -0.55(1-)7] = 1.675
Here = y/x must be found by trial and error. However for values near 1, (1-)7
is negligible compared to 7. Therefore a very good approximation is 7 = 1.675, =
1.6751/7 = 1.076
b) Using the flow rules, Eq.(13-12) for 1948 Hill with z = 0 and
y = x, y/x = [(R/P)]/[1] = 0.55/0.89 = 0.618
Using the flow rules, Eq.(13-24) for the new criterion with z = 0, y = x, and a = 8
y/x = (R/P)[7 -P(1-)7]/[1 -R(1-)7]
= 0.618[7 -0.89(1-)7]/[1 -0.55(1-)7]
= 0.618[1 ]/[1] = 0.618

13-12 For biaxial tension (y = x or y = x) the yield criterion, Eq. (13-18) becomes
x/X = [(R+1)/2]1/a.
For plane-strain (y = 0), the flow rule Eq. (13-19) predicts
|y|a-1 - R(x - y)a-1 = 0.
When a is an even integer, the absolute magnitude signs are not required, so =
y/x = R1/(a-1)/(1 + R1/(a-1)). The yield criterion, Eq. (13-18)
can be expressed as: xa[1 + a + R(1-)a] = (R+1)Xa
so x/X = {(R+1)/[1 + a + R(1-)a]}1/a
The ratio, , or , can be written as = {2/[1 + a + R(1-)a]}1/a
where = y/x = R1/(a-1)/[1 + R1/(a-1)]
Substituting various values and plotting:
13-13 It is easiest to compare these variables for conditions of 3 = 0, in which
case = 22/1 - 1 = 2 - 1 (where = 2/1). Substituting 3 = - 2 - 1, can be
expressed as = 2(2 2+ 1)/(2 1+ 2) -1 = 32/(21+ 2).
Substituting = 2/1, = 3/(2+ ). We can assume values of between 0 and 0.5,
find = 2 - 1, use the flow rules to find , and then calculate
= 3/(2+ ). For von Mises, = (2 -1/2)/(1 -2/2) = (2-1)/(2-), so
= 3/(2+ ) = 3[(2-1)/(2-)]/[2+(2-1)/(2-)] = 3[(2-1)]/3 = (2-1) = . (For Mises =
)
For Tresca, 2 = 0 for -1 0, so = 0 and = 0.
For the newer criterion, the flow rules (eq. 26) with R= P = 1, give = d2/d1 = [ya-1+
(y- x)a-1] [xa-1+ (x- y)a-1],
= [a-1-(1- ) a-1]/[1+ (1- )a-1].

13-14 a) 1 = Ln(6.11/5) = 0.2005, 2 = Ln(4.87/5) = -.0263

b) Using the flow rules, Eq.(13-12) for 1948 Hill with z = 0 and R = P, y/x = =
[2 + R(2 - 1)]/[R(1 - 2)+ 1] = [ + R( - 1)]/[R(1 - )+1]
[R(1 - )+ 1] = [ + R( - 1)]; [R +1 + R] = R + R;
= R(1 + )/[R(1 + ) +1]
Substituting = -.0263/0.2005 = -0.1314 and R = 1.8,
= 1.8(1 -0.131)/[1.8(1 -0.131) +1] = 1.564/2.564 = 0.610
c) From the flow rules, Eq.(13-31),
= dx/dy = [ya-1+R(y -x)a-1]/[ xa-1+R(x -y)a-1] =
= [a-1+R( - 1)a-1]/[1+ R(1 - )a-1] =
-0.1314 = [5+1.8( -1)5]/[1+ 1.8(1 - )5]
For small , = [R( -1)a-1]/[1- R ( -1)a-1];
R( -1)a-1 = [1- R ( -1)a-1],
R( -1)a-1(1+ ) = , ( -1)a-1 = /[R (1+ )]
( -1)5 = -0.1314/[1.8(1 -0.1314)] = -0.084; ( -1) = -0.609; = 0.391
[Note the calculated stress ratio depends heavily on which yield criterion is used.]

CHAPTER 14

14-1; With constant thickness the surface areas of the blank and final cup are equal.
r12 + 2r1h = ro2; 2r1h = ro2 - r12 ;
h/r1 = [(ro/r1)2-1]/2 = [(do/d1)2-1]/2. h/d1 = (1/2) h/r1 = [(do/d1)2-1]/4.
for do/d1 = 1.8, h/r1 = 0.56; for do/d1 = 2, h/r1 = 0.75;
for do/d1 = 2.25, h/r1 =1.016; for do/d1 = 2.5, h/r1 = 1.312.

14-2 a) LDR = exp{[(R +1)/2]1/2}

Differentiating,
d(LDR)/dR = exp{[(R + 1)/2]1/2}(1/2)[(R + 1)/2]-1/2(1/2).
Simplifying and substituting = 0.75 and R = 1,
d(LDR)/dR = (/4)exp{[ (R+1)/2]1/2}/[(R+1)/2]-1/2 =
(.75/4)exp(.75)/1 = 0.397
b) with LDR = exp{[2R/(R+1)]0.27}
d(LDR)/dR =
exp{[2R/(R+1)]0.27(0.27)[2R/(R+1)]1-0.27[(2/(R+1) - 2R/(R+1)2]
Now substituting: d(LDR)/dR R = [exp(0.75)](0.75)(0.27)[1- 1/2)] = 0.214
c) Here the best guess of for the slope at R = 1 was drawn.
for the Whitely data d(LDR)/dR = 0.2 near R = 1,
for the Wilson & Butler data, d(LDR)/dR = 0.25 near R = 1,
and for the Atkinson data, d(LDR)/dR = 0.18 near R = 1
All of these are much closer to to the slope from part (b) than from part (a).

14-3 a) For plane strain with y > 0 and y = 0, Eq. (13-19) reduces to:
ya-1 - R(x - y)a-1 = 0, so ya-1 = R(x - y)a-1, y = R1/(a-1)(x - y),
y = x R1/(a-1)/[1 + R1/(a-1)],
Substituting into the yield criterion, Eq. (13-18), with y > 0,
xa + xa{R1/(a-1)/[1 + R1/(a-1)]}a + Rxa{1 - R1/(a-1)/[1 + R1/(a-1)]}a =
(R + 1)Ya which simplifies to
x = Y(R + 1)1/a[1 +R1/(a-1)]/{[1 + R1/(a-1)]a + R1/(a-1)+ R]1/a
For plane strain with y = - x and z = 0, the yield criterion, Eq. (13-18) reduces to:
2xa + R(2xa) = (R + 1)Ya, or 2x = 2(R + 1)1/aY/(2 + 2aR)1/a
= x(y = 0)/[2x(z = 0)] =
= Y(R + 1)1/a[1 +R1/(a-1)]/{[1 +R1/(a-1)]a + R1/(a-1)+ R]1/a/
[2(R + 1)1/aY/(2 + 2aR)1/a]
= (2 + 2aR)1/a[1 +R1/(a-1)]/<2{[1 +R1/(a-1)]a + R1/(a-1)+ R]1/a}>
b) d(LDR)/dR = d(LDR)/d.(d/dR)
d(LDR)/d = exp(), for R=1, = 1, so d(LDR)/d = exp() and
with = 0.75, d(LDR)/d = 0.75exp(0.75) = 1.5877
To find d/dR, let = u/v where u = (2 + 2aR)1/a[1 +R1/(a-1)],
so du = (1/a)[1 +R1/(a-1)](2 + 2aR)1/a(2)a + (2 + 2aR)1/aR(2-a)/(a-1)/(a-1)
and v = 2{[1 +R1/(a-1)]a + R1/(a-1)+ R]1/a} so
dv = (2/a){ [1 +R1/(a-1)]a + Ra/(a-1) + R}(1-a)/a .
{[1 +R1/(a-1)]a-1(a)/[(a-1)R(2-a)/(a-1)] + (a)/[(a-1)R1(a-1) + 1}
For R = 1, these simplify to:
u = 2(2 + 2a)1/a; du = [(2/a)(2a)(2 + 2a)(1-a)/a] + (2 + 2a)1/a/(a-1)
v = 2(2 + 2a)1/a = u
dv = [(2/a)(2 + 2a)(1-a)/a][(2 + 2a-1)a - 1]/(a-1)
d/dR = (vdu - udv)/v2, but with u = v when R =1, /dR = (du - dv)/v
Numerical evaluation with d(LDR)/d = 1.5877 gives:
 a du dv u=v d/dR d(LDR)/dR
2 4.083 2.858 4.899 0.250 0.397
4 1.602 0.744 4.120 0.208 0.331
6 1.052 0.414 4.021 0.159 0.252
8 0.783 0.288 4.004 0.124 0.196
10 0.6216 0.223 4.001 0.100 0.159
The exponent a = 8 results in the best fit with the data.

14-4

Expanding, exp(-/2) = 1- /2 + (/2)2/2! - (/2)3/3! + ... 1- /2

So Fd - Ff Fd/2

14-5 The flow rules, Eq. (13-14), with y = 0 and z = 0 reduce to:
(R + 1)y - Rx = 0, or y = xR/(R + 1). Substituting into the yield criterion, Eq.(13-
13), [xR/(R + 1)]2 + x2 + R[x - xR/(R + 1)]2 = (R + 1)X2;
x2(2R2 + 3R + 1)/(R + 1)2 = R + 1)X2;
x2 = X2(R + 1)2/(2R + 1); x = X(R + 1)/(2R+1)

14-6 a) The volume of the can is v = d1tfhf + (d12/4)to where d1 = (27/16) =

2.4375 in., hf = 5.25, to = 0.016 and tf = 0.005in.
The volume of the blank is v = (do2/4)to
Equating blank and can volumes, (do2/4)to = d1tfhf + (d12/4)to.
do = {[d1tfhf + (d12/4)to](4/to)}1/2 = 4.684.
b) If no redrawing step were used, initial drawing ratio would be 4.684/2.375 = 1.92.
Yes, a redraw step is required. One should be sufficient.
c) Drawing and redrawing without thickness change would produce a can with walls
of 0.016 in instead of 0.005 in. This is a thinning strain of Ln(16/5) = 1.16. The heavy
cold reduction prior to drawing produces a material at the start of drawing that has very
little work hardening left. Assume n = 0. Then from Fig 14-16, the max ironing reduction
is r = 0.33 which is equivalent to a maximum strain per ironing pass of Ln[1/(1-r) =
0.400. A total ironing strain would then require three separate stages.
d) After drawing and redrawing the cup height, h2, would be such that h2 =
df[(do/df)2 - 1]/4 = 1.637 in.
Let us assume that half of this height is attained in the initial draw so after the initial
draw h1 = 0.82 in.
Let us also assume that each ironing stage produces the same strain, (1.16/3) = .387.
Then After the first ironing h3 = h2exp(.387) = 1.637(1.472) = 2.409, then h4 =
1.637(2.409) = 3.547 and h5 = hf = 1.637(3.547) = 5.22
Then the total stroke would be h1 + h2 + h3 + h4 + h5 = 10.8 in.
(The answer may differ from this depending on how the diameter reduction was distributed between the
cupping and redrawing and how the wall thinning was distributed between the ironing stages.)

14-7 a) For a non-workhardening material, the work/volume, dW/dV = xx

because z = 0 and y = 0. [Note that W = (dW/dV)dV where dV = d1dzdh.]
In bending x z/(r + t/2) where z is the distance from the mid-plane and (r + t/2) is the
radius of curvature at the mid-plane. Therefore the total work in bending per unit punch
stroke is (dW/dh) = 2d1t/2xzdz/(r + t/2) = 2d1x(t/2)2/[2(r + t/2)]. Unbending
requires the same amount of work so the total bend-unbend work is
dW/dh = 2d1x(t/2)2/(r + t/2).
The bending and unbending is in plane strain, (y = 0), so
x = X(R + 1)/(2R+1)
dW/dh = 2d1(t/2)2X(R + 1)/(2R+1)/(r + t/2).
b) for R = 1, t/2 = 0.016 and r = 0.25,
dW/dh = X(2)(1)(0.016)2(2)/[(3)(0.25 + 0.016)] = 0.00698X
whereas the total drawing force is Fd = (1/)d1tf ln(d0/d1)
where from Eq.(14-4), f = X[(1 + R)/(R + 1/2)]1/2 = 1.155X
Fd = 1.155X(1/)d1t ln(d0/d1) = 1.155X(1/)(2)(0.016) ln(2.2) = 0.0915X/.
Assuming = 0.75, Fd = 0.122X. Therefore the work in bending and unbending
represents 0.00698/0.122 = 5.7% of the total work. (This fraction of course depends on
the radius of the die lip relative to the sheet thickness.)

14-8 a) Much of the energy required for the deformation work is supplied by the
fluid pressure acting on the edges of the flange, so the tensile stress in the wall is
reduced.
b) The work done by the fluid pressure per unit punch travel, dh, is (dW/dh)fluid =
2rt(-dr/dh)P where r is the current outer radius of the flange. Since 2r1h + r2 =
ro2, 2r1dh = -2rdr or -dr/dh = r1/r. Substituting (dW/dh)flange = 2r1tP.
The total rate of work per punch travel is
dW/dh)total = (1/)2r1tf ln(r/r1)
The force supplied by the punch, Fd = dW/dh)total -(dW/dh)fluid
Fd = (1/)2r1tf ln(r/r1) - 2r1tP = 2r1t[(1/)f ln(r/r1)- P]
At the drawing limit, for a non-work hardening material, r = ro, and Fd = w2r1t so w
= (1/)f ln(r/r1)- P,
For isotropy according to Mises w = f = 1.155Y. Substituting:
P = 1.155Y[1- (1/) ln(r/r1)]
With Y = 40,000, r/r1 = 3 and = 0.75, P = 21,500 psi
(This is a very high fluid pressure and would require a vessel with very thick walls.)

14-9 Substituting = [2R/(R+1)]0.27 into LDR = exp(),

LDR = exp( [2R/(R+1)]0.27).
Now calculating LDR for various combinations of and R and plotting on Microsoft
Excel, it is clear that = 0.8 gives the best fit

14-10 For each material, calculate 2R/R . Compare the values of h/h and 2R/R for
each material with Fig. 14-12.
h45/h0 = [1 + (d1/d0)1/(P+1)]/[1 + (d1/d0)1/(Q+1)]
h90/h0 = [1 + (d1/d0)1/(P+1)]/[1 + (d1/d0)1/(R+1)]
h/h = [2h45-(h0 +h90)]/[2h45+(h0 +h90)]
R/R = [2Q-(R + P))]/ [2Q+(R + P))]
a) h45/h0 = 0.954 h90/h0 = 0.992
h/h = -0.0216 R/R = -0.151
b) h45/h0 =1.0106 h90/h0 = 0.9875
h/h = 0.0084 R/R = +0.103
c) h45/h0 = 1.0568 h90/h0 = 1.0318
h/h = 0.0197 R/R = +0.231
d) h45/h0 = .946 h90/h0 = 1.000
h/h = -0.0276 R/R = -0.272
14-11 At the outside of the blank, the stress state during drawing is uniaxial
compression. The compressive strain is y = Ln(d1/do). Then assuming isotropy, z =
Ln(tw/to) = (-1/2)y = (-1/2) ln(d1/do)
tw/to = (d1/do)-1/2
For (do/d1) = 1.8, tw/to = 1.8 = 1.34

CHAPTER 15

15-1 Eq.(15-15) gives 1* = 2n(1 + + 2)/[(1+ )(22 - +2)]

The flow rules for Mises give = d2/d1 = (2 -1/2)/(1 -2/2) = (2-1)/(2-). Now
substituting for ,
1* = A/B where A = 2n[1+(2-1)/(2-)+(2-1)2/(2-)2] and
B = [(2-1)/(2-)+1][2(2-1)2/(2-)2-(2-1)/(2-)+2]
Expanding and simplifying:
1* = 2n[1-+2)/(2-)]/[42 - 7 +4)(1+)]
As a check, note that for = 0 (uniaxial tension), for = 1/2 (plane-strain tension), and
for = 1 (balanced biaxial tension), 1* = n.

15-2 = arctan[(R+1)/2]1/2
Substituting R = 1.6, = 51.89; and for R = 1.8, = 51.28
This is a difference of only 0.61. One would have to measure to an accuracy of about
0.3 to be sure they were different. Such accuracy in measuring the angle of a neck
isn't possible so this method is not used to find R.

15-3 3 = C, and 3 = -1-2, so 1 = -C - 2.

Converting to engineering strains, 2 = Ln(1+e2) or e2 = exp(2) -1 and
e1 = exp(1) -1 = exp(-C-2) -1 = exp[-C- Ln(1+e2)] -1
At e2 = 0, -C = Ln(e1+1) = Ln(1.43) so e1 = 1.43/(1+e2) -1.
This criterion is very good for e20 but very bas for e2>0

15-4 The criterion is the same as in 15-3 for e2 > 0 where

|i|max = -3 (where 3 is negative) and the criterion is the same as in Prob 15-3. For
e2 < 0, 1 = |i|max so the criterion is 1 = C. (horizontal straigth line.) Matching at e2 =
0, C = 0.43. Neither regime makes any sense.

15-5 This corresponds to 1 = Ln3 = 1.099 or e1 = 2.0. Although this reduction is in

excess of those indicated on the forming limit diagram for plane strain (Fig 15-7), it
must be realized that the forming limit diagrams are determined under plane-stress
conditions, (z = 0) and are therefore applicable only under those conditions. For
ironing, z is very compressive so the FLDs are not applicable. (This is also true for
extrusion, rolling, etc.)

15-6 On the outside surface both 2 and 1 are larger than art the midplane by the
bending strain, = (t/2)/R. Substituting R = 51 mm. for a 102 mm diameter
hemispherical punch and t = 0.8 mm, = .004 2 and 1 = 0.304 and 2 = 0.004. (The
change is about 1/2%)
CHAPTER 16

16-1 FA = Fbexp(/2), AtA = BtBexp(/2)

substituting ti = toexp(-i) and i = kin,
Anexp(-A) = Bnexp(-B)exp(/2),
or = (2/) ln{(A/B)nexp(-B + A)}
Substituting n = 0.22,A = 0.180 and B = 0.040, = 0.12

16-2. Solving by trial and error, = 53.13, = R/sin, arc length = 2 = 2R/sin
a) r = Ln[(arc length)/(2R)] = Ln[(2R/sin)/(2R)] = Ln[/sin] =
= Ln[(53.13/180)/sin 53.13] = 0.148

= exp(r), = s/ and r = siny = sin(s/)

c = Ln[(2r)/(2ro)] = Ln[sin(s/)/ro]
c = Ln{1.250Rsin[roexp(r)/(1.25R)/ro} =
= Ln{(1.25R/ro)sin(1.25R/ro)-1exp(0.01476)}
16-3 Assume von Mises and that = K n. The walls will deform under plane strain,

so = 1.155w, and w = 1.155 . Therefore, w = 1.1551+nKwn. The deformation

under the punch will be in biaxial tension, and = |b| where b is the thinning strain

and = b = Kbn.

The relative force in the walls and under the dome are given by Fw = Fdexp(), or
Fw/ Fd = exp(0.12/2) = 1.207. Neglecting the difference in radius between the wall and
the material under the dome,
wtw = 1.207btb. (a)
When the wall necks, tw = toexp(-w) = toexp(-n) = toexp(-0.25)
tw = 0.779to (b)
and w = 1.1551+nKn = 1.1551+nKnn = 1.1551.25k(0.25)0.25
w = = 0.8467K (c)
Under the punch, b = Kb0.25 (d) , and tb = toexp(-b). (e)
Substituting, (b), (c), (d) and (e) into (a),
0.8467K0.779to = 1.207Kb0.25toexp(-b).
0.5465 = b0.25exp(-b).
Solving by trial and error, b = 0.193

16-4 Consider force balances on one pin just before unloading and during unloading
just before there is unbending. The normal force, N, should be the same if no
unbending has occurred.
Ncos + Nsin = F1/2 Ncos - Nsin = F2/2
Solving for 2N and equating,
2N = F1/(cos + sin) = F2/(cos - sin)
F1(cos - sin) = F2(cos + sin), sin(F1 + F2) = cos(F1 - F2)
= (cos/sin)(F1 - F2)/(F1 + F2) = cot(F1 - F2)/(F1 + F2)

16-6 If the thickness is the same over the bulged surface, the thickness strain, 3 =
ln(A/Ao) where Ao = R2 and where
A is the area of the spherical sector,
A = 22sind = 22(1+cos)
From Problem 16-5, cos = (-h)/ = 1 - h/, so 1+cos = 2 - h/
h/ = 2h2/(h2 + R2), so 1+cos = 2 - 2h2/(h2 + R2) = 2R2/(h2 + R2)
and 2 = (h2 + R2)2/(4h2).
Substituting A = 22(1+cos) = 2[(h2 + R2)2/(4h2)][2R2/(h2 + R2)] =
4R2)(h2 + R2)/(4h2)
A/Ao = )(h2 + R2)/h2 = [1 + (R/h)2]
3 = ln [1 + (R/h)2]

16-7 Consider the change of shape as the specimen necks completely to zero
thickness. A region, originally to by to necks into two triangles. The total area must
remain unchanged, so to2 = (1/2)toL, L = 2to
tan = to/L = 1/2, = arctan(1/2) = 26.6