MECH 6511 MECHANICAL FORMING OF METALS

ASSIGNMENT 1

Due date: January 26, 2011

Part A: (5 marks)

1. Particulate processing of metals and ceramics involves which of the following steps
(two best answers): (a) adhesive bonding, (b) deformation, (c) forging, (d) material
removal, (e) melting, (f) pressing, and (g) sintering?

2. Deformation processes include which of the following (two correct answers): (a)
casting, (b) drilling, (c) extrusion, (d) forging, (e) milling, (f) painting, and (g)
sintering?

3. Which one of the following is a machine used to perform extrusion: (a) forge hammer,
(b) milling machine, (c) rolling mill, (d) press, (e) torch?

4. Which one of the following crystal structures has the fewest slip directions and therefore
the metals with this structure are generally more difficult to deform at room temperature:
(a) BCC, (b) FCC, or (c) HCP?

5. Grain boundaries are an example of which one of the following types of crystal structure
defects: (a) dislocation, (b) Frenkel defect, (c) line defects, (d) point defects, or (e)
surface defects?

Part B: (5 marks)

1. Briefly describe why different crystal structures exhibit different strengths and
ductilities.

2. Two physical properties that have a major influence on the cracking of workpieces,
tools, or dies during thermal cycling are thermal conductivity and thermal expansion.
Explain why.

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Part C: (20 marks)

1. The flow curve parameters for a certain stainless steel are strength coefficient = 1100
MPa and strain-hardening exponent = 0.35. A cylindrical specimen of starting
cross-sectional area = 1000 mm2 and height = 75 mm is compressed to a height of 58
mm. Determine the force required to achieve this compression, assuming that the cross
section increases uniformly.

2. A batch of annealed steel has just been received from the vendor. It is supposed to have a
tensile strength in the range 60,000 - 70,000 lb/in2. A Brinell hardness test in the
receiving department yields a value of HB = 118. (a) Does the steel meet the
specification on tensile strength? (b) Estimate the yield strength of the material.

3. A strip of metal is originally 1.5 m long. It is stretched in three steps: first to a length of
1.75 m, then to 2.0 m, and finally to 3.0 m. Show that the total true strain is the sum of
the true strains in each step, that is, that the strains are additive. Show that, using
engineering strains, the strain for each step cannot be added to obtain the total strain

4. A material with a yield stress of 70 MPa is subjected to three principal (normal) stresses
of ߪଵ , ߪଶ = 0, and ߪଷ = −ߪଵ /2 What is the value of ߪଵ when the metal yields according
to the von Mises criterion? What if ߪଶ = ߪଵ /3

5. A horizontal rigid bar c-c is subjecting specimen a to tension and specimen b to

frictionless compression such that the bar remains horizontal. (See the accompanying
figure.) The force F is located at a distance ratio of 2:1. Both specimens have an original
cross-sectional area of 1 in2 and the original lengths are a = 8 in. and b = 4.5 in. The
material for specimen a has a true-stress-true-strain curve of ߪ = 100,000߳ ଴.ହ
Express the true stress and the true strain of material b in terms of K and deflection x.