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Faculty of Engineering and Applied Science

MANE 3190U: Manufacturing and Production Processes


Instructor: Dr. Sayyed Ali Hosseini

Assignment # 1
First Name: _________________

Last Name: ______________

Student ID: _________________

Section: _________________

Date Assigned:

Friday, September 25th, 2015

Date Due:

Friday, October 2nd, 2015


Q1 (25)

Q2 (25)

Q3 (25)

Q4 (25)

Total (100)

Instructions for completion:


Clearly write your name and student number at the top of this title page and each solution
page.
Staple all solution pages to the title page of the assignment.
For the long answer questions, write out the entire solution (do not skip steps).
Any form of plagiarism will not be tolerated.
Late submissions will not be accepted.

Question #1
Consider a cubic workpiece of rigid perfect plastic material with side length . The cube is
deformed plastically to the shape of a rectangular parallelepiped of dimensions , , . Show that
the volume constancy requires that the following expression be satisfied: + + = 0.
Hint: , , are true strains.

Solution #1:
:

:
:

= ln

+ ln

+ ln

= ln

" = ln

" = ln[1] = 0

Question #2

A strip of metal is originally 1.5 m long. It is stretched in three steps: first to a length of 1.75 ,
then to 2.0 , and finally to 3.0 . 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.
Solution #2:
The true strain is given by

= ln +, ., therefore:
-

= ln /

1.75
0 = 0.1541
1.5

= ln /

2.0
0 = 0.1335
1.75

3.0
= ln / 0 = 0.4055
2.0

The sum of these true strains is


step 1 to 3 is

= 0.1541 + 0.1335 + 0.4055 = 0.6931. The true strain from


3.0
= ln / 0 = 0.6931
1.5

Therefore the true strains are additive. Using the same approach for engineering strain, we obtain
=
=

The sum of these strains is

1.75 1.5
= 0.1667
1.5

2 1.75
= 0.1429
1.75
=

32
= 0.5
2

= 0.8096. The engineering strain from step 1 to 3 is


=

3 1.5
=1
1.5

Note that this is not equal to the sum of the engineering strains for the individual steps.

Question #3

A metal has a strain hardening exponent of 0.22. At a true strain of 0.2, the true stress is
20,000 678. (a) Determine the stress-strain relationship for this material. (b) Determine the true
and engineering ultimate tensile strength for this material.
Solution #3:
9=:

= 0.22

9 = 20000 678, = 0.20 20000 = :=0.20>

: = 28500 678

Therefore, the stress-strain relationship for this material is


9 = 28500

678

To determine the ultimate tensile strength for the material, realize that the strain at necking is equal
to the strain hardening exponent, or = . Therefore,
?@ABCDE

9D,BFGHI = :

= 28500=0.22>

= 20400 678

The cross-sectional area at the onset of necking is obtained from


J
ln /
0=
J;EKL
and the maximum load is

= 0.22 J;EKL = J

M .

N = 9J = 9D,B J;EKL = 20400 J


As a result:

?@AE;O

9D,BIPQ =

S-

M .

T U SS-

= 16370J

= 16370

Question #4
Calculate the work done in frictionless compression of a solid cylinder 40 mm high and 15 mm in
diameter to a reduction in height of 75% (it means the final length will be one quarter of the initial
length) for the following materials: (1) 1100-O aluminum, (2) annealed copper, (3) annealed 304
stainless steel, and (4) 70-30 brass, annealed. The material properties for these materials are as
follows:

Hint: as the strain in compression is negative, use its absolute value for calculation of work to
prevent complex numbers.
Solution #4:
Since the reduction in height is 75%, the final height is 10 mm and the value of the true strain is
= ln / 0 = ln /

10
0 = 1.386
40

The values are then calculated from as follows, e.g. for 1100-O aluminum, where : is 180 VN
and is 0.20, is calculated as:
=

;W

+1

180 =1.386>
1.2

= 222 VX/

The volume of specimen is calculated as


=Z

= Z 0.0075 0.04 = 7.069 10MT

The work done is the product of the specific work, , and the volume,
can be tabulated as follows.

. Therefore, the results