Chapter 7

7-1 A coil of steel, 252 mm wide and 3 mm thick is drawn though a pair of dies of
semi-angle 8 to a final thickness of 2.4 mm in a single pass. The outlet speed is 3.5 m/s.
The average yield strength is 700 MPa and the friction coefficient is 0.06. Calculate the
power in kw consumed.
Solution: d = 2k[(1+B)/B][1-exp(-B)]. Substituting B = cot = 0.06cot8 = 0.427, 2k
= 1,154(700) and = ln(3/2.4) = 0.223, d = 245 MPa.
Power =d(velocity)(crossectional area) = (245 MPa.)(3.5m/s)(0.252 m)(0.0024) = 52
kw.

7-2 An efficiency of 65% was found in a rod-drawing experiment with a reduction of

0.2 and a semi-die angle of 6.
a) = i/d = Yave/d Substituting eq. 7-14 for d,
h = Yave/{Yave[1+B)/B][1-exp(-B)]} = B/(1+B)]/[1-exp(-B)].
Now substituting e = _n[1/(1-r) = 0.223 and
h = .65, 0.65/0.223 = [B/{(1+B))[1-exp(-0.223B)]}
Solving by trial and error, B = 0.654 but B = m/tan, so with a = 6o, m= Btan6o = 0.0687
b) Substituting B = 0.654 and = _n[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 Estimate the force required to coin a U. S. 25 piece. Assume that the mean flow
stress is 30,000 psi, the diameter is 0.95 in. and the thickness after forming is 0.060 in.
Solution: Assume sticking friction because embossing wont allow sliding.
P = Y[1+1.154(0.475)/2x0.60)] = 132,800 psi
F = 132.8x103((0.475)2 = 94,200 lbs

7-4 Figure 7.26 shows a billet before and after hot forging from an initial size of 2.5
mm x2.5 mm x25 mm to 5 mm x1.25 mm x 10 mm. This is accomplished by using a flat-
face drop hammer. Sticking friction can be assumed. For the rate of deformation and the
temperature, a flow stress of 180 MPa can be assumed.
a) Find the force necessary.
b) Find the work required. (Remember that work = FdL and that F changes with L.)
c) From what height would the hammer of 3 kg have to be dropped?
d) Compute the efficiency, .

Chapt. 7 Slab analysis and Friction 87

 Figure 7.26 Compression in Problem 7-4.

Solution: a) Using the final dimensions, F = Pav(0.025)(0.005) = 1.154(18)[1 + 5/

(4x1.25)] = 41.5 MPa
b) b = (bo)(ho)/h
Work = Fdh where F = 2k(1+b/4h)bh = 2k(1+(bo)(ho)/h2)L(bo)(ho)/h =
2k(1+(bo)(ho)/h2)L(bo)(ho)/h = 2kL(bo)(ho)/h + 2k(bo)2(ho)2/h3)L
Work = 2kL(bo)(ho)dh/h + 2kL(bo)2(ho)2)dh/h3) = 2kL(bo)(ho)ln(h/ho) + 2kL(bo)2(ho)2)[-
ho-2+h-2) = (1.154)(180x106)(0.025)(0.0025)(0.0025){ln(2.5/1.25) + [0.0025)-2- 0.00125)-
2
]/(-2)}
= 0.00325{0.693 + 1.5) = 71.3 J
c) 71.3 = ghm; h = 71.3J/[(10 m/s2)(3 kg)] = 2.4 m
d) Wi = (vol) = 180MPa(0.0025)(0.0025)(0.025) = 28 J; = 2.8/7.13 = 39%

7-5 Two steel plates are brazed as shown in Figure 7.27. The steel has a
tensile yield strength of 70 MPa and the filler material a with tensile yield
strength of 7 MPa. Assuming that the bonds between the filler and the steel do not
break. Determine the force necessary to cause yielding of the joint.

Figure 7.27 Brazed joint for

Problem 7-5.

Solution: P = 2k(1+b/4h) = 2k(1+3/8) = 70 MPa(0.003m)(0.050m)(1.154)(1.375) = 16.6

kN

Chapt. 7 Slab analysis and Friction 88

7-6 Figure 7.28 shows a thin lead ring being used as a gasket. To insure an acceptable
seal the gasket must be compressed to a thickness of 0.25mm. Assume that the flow
stress of lead is 15 MPa and strain hardening is negligible. Find the required force.

Figure 7-28. Lead gasket for Problem 7-6.

Solution: Substituting b = 0.004m and h = 0.00025m, into P = 2k(1+b/4h) = (1.154)(15)
(1+4/0.25) = 294 MPa. F = 294x106(0.025)(0.004) = 92.4 kN

7-7 The derivation of equation 7.11 assumed a constant coefficient of friction. Derive
an equivalent expression assuming sticking friction.
Solution: Making a force balance,
[x(r+dr)2 + (r+dr)2]dx +mk(2r)dx + P(2r)tandx = r2x
Expanding, neglecting second order differentials and simplifying
2xrdr + r2dx + 2rxdr +2mkrdx + 2rPtan = 0
Substituting P = Y - x and dx = dr/tan,

7-8 Magnetic permalloy tape is produced by roll flattening of drawn wire. The final
cross section is 0.2 mm by 0.025 mm. It is physically possible to achieve this cross
section with different rolling schedules. However it has been found that the best magnetic
properties result with a maximum amount of lateral spreading. For production the rolling
direction must be parallel to the wire axis. Describe how you would vary each of the
parameters below to achieve the maximum spreading.
a) roll diameter
b) reduction per pass
c) the friction
d) back and front tension

Chapt. 7 Slab analysis and Friction 89

 rolling direction

0.025 mm

0.2 mm

Figure 7.29 Permalloy tape (Problem 7-8)

Solution: To maximize spreading, the contact length should b a long as possible.
a) use as large roll diameter as possible
b) maximize the reduction/pass. (use only one pass)
c) If the contact length is greater than the width, high friction will promote spreading
d) Use no back or front tension

*7-9A metal with a flow stress of 35 MPa is to be drawn from a diameter of 25 mm to 20

mm through a die of 15 semi-angle. Calculate the necessary drawing stress if:
a) The conditions are frictionless
b) = 0.20.
Solution: = ln(do/d) = 0.223
a) d = = (35)(0.223) = 7.8 MPa
b) Using Sachs analysis with B = (0.20)(cot15) = 0.746,
d = (1.154)(35)[(1+0.746)/0.746][1-exp(-0.46x0.223)] = 14.5 MPa

7-10 Consider the rolling of a sheet 15 cm wide from a thickness of 1.8 mm to 1.2 mm
in a single pass by steel rolls 20 cm in diameter. Assume a friction coefficient of 0.10 and
a flow stress of 125 MPa.
a) Calculate the roll pressure if roll-flattening is neglected.
b) Calculate the roll pressure taking into account roll flattening.
c) Estimate the minimum thickness that could be achieved.
Solution: a) Substituting = 0.1, h = 0.015 and L = (Rh) = (0.010x0.0006 =0.025
so h/L = 0.1667 and = 125 MPa into P = [h/(L)][exp(h/L) 1] , P = 136 MPa

Chapter 8

8-1 Find Pe/2k for Figure 8.2 if is 80 and compare with Figure 8.3.
Solution: AB = 1/sin80 = 1.015. V*AB/sin30 = V0 /sin(50), V*AB/V0 = sin30/sin50 =
0.653. The horizontal component of BC is 3/2-1/2 = 0.732. = (1/2)/arctan (3-1)/2] =
36.2
BC= [(1/2)2+ (0.7322] = 0.886, V*BC/sin80 = V0 /sin63.8; V*BC/V0 = 1.098
dW/dt = (1.015)(0.653) + (0.886)(1.098)k = 1.635k
Pe/2k = 0.818. This agrees with Fig 8-3

8-2 Calculate Pe/2k for the plane-strain frictionless extrusion illustrated in Figure
8.14. Triangles ABC and CDE are equilateral.

Chapt. 7 Slab analysis and Friction 90

 Figure 8.14 Upper-bound field
for plane strain drawing for
Problem 8-2.

Solution: The hodograph is

V0
30 30 30

V*AB V*BC
60
V*CD
V*ED

60 60

AB= BC=6, CD = ED=3, V*AB =V0(1/3), V*BC =V0(2/3, V*CD = (2/3)V0, V*ED
=V0(4/3).
Pe/2k = (1/2)[6(1/3) + 6(2/3) + 3(2/3) + 3(4/3)]0 = (183)10.4 =

8.3 On which discontinuity in Figure 8.14 is the largest amount of energy expended?
Solution: AB and ED A B.

8.4 *Draw the hodograph corresponding to the frictionless indentation illustrated in

Figure 8.15.

Figure 8.15 Upper-bound

field for indentation for
Problem 8-4.

Solution:

V*DC
V*BC
V*DE

V*AB

Vp
V*AC

8-5 For the plane-strain compression illustrated in Figure 8.16, calculate Pe/2k for
L/H values of 1, 2, 3, and 4. Assume sticking friction.

Chapt. 7 Slab analysis and Friction 91

 O
A=
A=
BB
C=
CD=
w(
h/
2)
(
1
/2)

Figure 8.16 Upper-bound

field for plane-strain
compression for Problem 8-
5.

8-6 Reanalyze Problem 8-4 if frictionless conditions prevailed.

Solution: No sliding occurs on the platen surface so the solution is the same.

8-7 For the indentation shown in Figure 8.7, Pe/2k = 2.89 if all the angles were 60.
Find Pe/2k if the angles OAB, ABC and BCD are 90 and the other angles are 45.
Solution: O A =A B =B C = CD =w /(
2 2 ), A C = w /2, V*OA = V*AB = V*BC = V*CD =
2Vp, V*AC = 2Vp
W = k (
V * S )= k[(4)w/(22)Vp +wVp) = P(w/2)Vp; P/2k = 2(1+1/2) = 3.414

8.8 Figure 8.17 shows an upper-bound field for a plane-strain extrusion. There are two
dead metal zones ADF and FEG.
a. Calculate Pe/2k for the field.
b. Determine the velocity inside triangle ABC.
c. Determine V*AC.
d. Compute the deformation efficiency.

Figure 8.17 Upper-bound

field for Problem 8.

Solution: First draw a hodograph.

0.502 or 50.2%
AB = 2/2, BC = 1/cos15 = 1.035, AC = (1/2)/sin60 = 0.577
V*AB = sin45/sin105 = 0.732, V*BC = sin45/sin30 = 1.414, V*AC = sin75/sin45 = 1.366,

Chapt. 7 Slab analysis and Friction 92

a) Pe(1)(1) = k[(2/2)(0.732) + (1.035)(1.414) +(0.577)(1.366)] = 2.762
Pe/2k= 1.38
b) VABC = V*AB = 0.732,
c) V*AB = 0.732,
= ln2/1.38 =

8-9 a. Use equation 8.27 to find the drawing stress, d, for an axisymmetric rod
drawing with reduction of 30%, a semi-die angle of 10 and a constant interfacial shear
stress of 0.1k. Assume the Tresca criterion.
b. Predict d using the von Mises criterion.

Figure 8.18 Illustration of

axisymmetric drawing for
Problem 8-9.

Solution:

8-10 Consider the upper-bound field in Figure 8.19 for an asymmetric extrusion.
a. Draw the corresponding hodograph.
b. Determine the angle, .

Figure 8.19 Illustration of an

asymmetric plane-strain
drawing for Problem 8-10.

Chapt. 7 Slab analysis and Friction 93

Solution: a)

V* EF
V3
V* DE
Vo

Ve
V1 V* AB

V*BD
V* DC

V* BC

b) tan = 0.5Vo/2.5Vo = 0.20, = 11.3.

8-11 For the plane-strain compression illustrated in Figure 8.20, calculate Pe/2k for L/h
values of 1, 2, 3, and 4. Assume sticking friction.

Figure 8.20 Upper-bound fields for plane-strain compression in Problem 8-11.

Solution: For L/h = 1, Pe/2k = 1,
Drawing a hodograph for L/h = 2,
V* AC

V* AB V*BC

Vup

V*AC= 2Vp, V*AB = V*BC = 2Vp, AB = BC = AC/2;

PeVpAC = k[V*ABAB + V*BCBC +V*ACAC] = k(2/2 + 2/2 + 2(1)]VpAC
Pe/2k = 2
Drawing a hodograph for L/h = 3,
V*OC

V*AB V* BC
V* OA
Vup

Chapt. 7 Slab analysis and Friction 94

V*OA = V*AB = V*BC = 2Vp, V*OC = 3Vp, OA = AB = BC = 2OC/3
PeVpOC = k[V*OAOA + V*ABAB + V*BCBC + V*OCOC] =
= k[(32)(2/3)VpOC +

8-12 For the indentation shown in Figure 8.7, Pe/2k = 2.89 if all the angles were 60.
Find Pe/2k if the angles OAB, ABC and BCD are 90 and the other angles are 45.
Solution: From the geometry of the field, OA = BC = CD = (2/2)OB and AC = OB.
From the geometry of the hodograph, V*OA = V*AB = V*BC = 2VP, V*AC = = 2VP, The
rate of external work on the right side of the field will be P(Vp)(OD)
P(Vp)(OB) = k[(V*OAOA + V*ABAB_+ V*BC BC + V*CD CD + V*AC C )
P(Vp)(OB) = k[3(2VP)((2/2)OB) + (2VP)(OB)] = k(3 + 2)(Vp)(OB)
Pe/2k = 2.5

8-13 A proposed upper-bound field for extrusion is shown in Figure 8.21. Draw a
hodograph to scale and determine the absolute velocity of particles in the triangle
bounded BCD.

Figure 8.21 Upper-bound field

for the plane strain extrusion of
Problem 8-13.

Solution:
Vo
Ve

V*AE
V*AD

V*DB V* BC

V*EA = 1/cos(67.8) = 2.647, VAED = tan(67.8) = 2.45, VDAB/sin22.2 = V*EA/sin45,

VDAB = 2.647sin22.2/sin45 = 1.414, tan(67.8) = VBCD/VDAB, VBCD =
VDABtan(67.8) = 1.414tan(67.8) = 3.465 downward

8-14 Figure 8.22 shows an upper-bound field for a plane-strain extrusion. There are
two dead metal zones ADF and FEG.
a. Calculate Pe/2k for the field.

Chapt. 7 Slab analysis and Friction 95

b. Determine the velocity inside triangle ABC.
c.Determine V*AC.
d. Compute the deformation efficiency.

Figure 8.22 A 2:1 extrusion

field for Problem 8-14.

Solution: First draw a hodograph

B
45 105
30

Ve Vo

A 105
V*BC V*AB

V* AC

45
60
C 75

AB = 2/2, BC = 1/cos15 = 1.035, AC = (1/2)/sin60 = 0.577

V*AB= sin45/sin105 = 0.732, V*BC= sin45/sin30 = 1.414, V*AC= sin75/sin5 = 1.366
a) Pe(1)(1) = k[(2/2)(0.732) + (1.035)(1.414) + (0.577)(1.366] = 2.77
Pe/2 k = 1.385
b) VABC = V*AB= 0.732
c) V*AC= sin75/sin5 = 1.366
d) = ln2/1.385 = 50.2%

8-15 Use equation 8.27 to find the drawing stress, d, for an axisymmetric rod drawing
with reduction of 30%, a semi-die angle of 10 and a constant interfacial shear stress of
0.1k.
a. Assume the Tresca criterion.
b. Assume the von Mises criterion.
Solution: d/2k = (o/2k + m/sin) + (2/3)tan. Substituting = .357 for a reduction of
30%, =10 and m = 0.1; d/2k = (o/2k + 0.576)(.357) + 0.1176.
a For Tresca o/2k = 1, d/2k = 1.576(.357) + 0.1176 = 0.68

Chapt. 7 Slab analysis and Friction 96

b For von Mises, o/2k = 1.15, d/2k = 0.74

8-16 Consider the plane-strain indentation illustrated in Figure 8.23. Assume that the
deformation in region AABB is homogeneous. There are discontinuities along AA and
BB.
a. Write an expression for V*AA and V*BB in terms of Vo, z and t.
b. What is the ratio of the energy expended on these discontinuities to the
homogeneous work?

Figure 8.23. Figure for

Problem 8-16.

Solution:
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 discontinuities dW/dt = kVPt
Rate of homogeneous work is dW/dt = (2k)[VP/(2t)](wt) = kVPw
shear work/homogeneous work = kVPt/(kVPw) = t/w

8-17 Figure 8.24 shows two different upper-bound fields for a 2:1 reduction by extrusion.
Regions ABC and EFG are dead-metal zones.
a. Calculate Pe/2k for both fields.
b. Determine the deformation efficiency, , for both cases.
c. What is the absolute velocity of a particle in triangle JGH?

Figure 8.24 Two

proposed upper-bound
fields for a plane-strain
extrusion with a 50%
reduction for Problem 8-
17.

Solution:
First draw the hodographs for both fields

Chapt. 7 Slab analysis and Friction 97

 A
Vo = 1

C
V*AC =2 V*AD = 1 V*DC =2

Let AD = 1. Then AC = CD = 1/2; Pext(1)(1) = k[2(1/2)(2) + 1(1)] = 3k,

Pext/2k = 1.5
= ln(2)/1.5 = 46.2%
E

Vo = 1

V*EG V* HG
J V*EJ V*JH
G

V*JG

Let Vo = 1, Then V*EG = sin60/sin75 = 01 + .897 = V*HG. V*EJ = sin45/sin75 = 0.732

=V*JG = V*JH . Let ho = 1. Then EG = HG = 2/2, EJ = JH = 0.5/sin60 = 0.577 and
JG/sin75 = EC/sin 60, so JG = (2/2)sin75/sin60 = 0.7887.
Pext/2k = (1/2)[2(.577)(0.732) + 2(0.707)(0.897) +(0.732)(0.7887)] = 1.345
= ln(2)/1.345 = 51.5%
c) The horizontal component of VGJH = 1 + V*JG/cos60 = 1.464.
The vertical component of VGJH = V*JG/cos60 = 0.845
VGJH = [1.4642 + 0.8452]1/2 = 1.690

Chapt. 7 Slab analysis and Friction 98