You have a 40 mm thick plate available (can be cut to size as needed) and your company possesses equipment with the following capabilities: 1. Hot closed die forging (MF = 4) (2) Hot open die forging (MF = 1.5) 3. Cold flat rolling (MF=3) 4. Hot flat rolling (MF = 4) 5. Cold extrusion 6. Hot extrusion 7. Cold wire drawing a) Select a combination of two sub-processes from the list above for the manufacture of the component shown in figure 1 on page 2! There is no requirement for the surface finish. Hot process b) For each sub-process, calculate the required processing force! Material parameters and a list of equations are provided on following pages. c) Indicate 2 methods to reduce the force requirement for each sub-process! add steps heat die lubricate 10 15 15 10 -All dimensions are in mm -Length in third direction = 10 mm Figure 1 17 Material: Low carbon steel Following process parameters apply: Coefficient of friction = 0.6 (hot) = 0.15 (cold) K = 600 MPa; C 300 MPa; n = 0.27; m = 0.13 Radius of rolls in rolling stand = 0.6 m Shear yield strength of low carbon steel = 110 MPa (hot) = 320 MPa (cold) Tensile yield strength of low carbon steel = 210 MPa (hot) = 620 MPa (cold) Ultimate tensile strength of low carbon steel = 410 MPa (hot) =820 MPa (cold) Forging speed 0.25 m/sec Roll surface speed = 1.2 m/sec Extrusion speed = 0.12 m/sec. Max. length of extruder = 5 m. a = 14 (for drawing) Taverage = K& n+1 F= OTaverage UR*w*MF F = *A*MF haverage In m ho Aoriginal & In Afinal L = R(ho-h) & = h Faverage 1.7 A, *OTaverage In = Vo hfaverage = Afprojected haverace In ho yield Taverage L A = Lxw F average = C (A) 2 [svin (original) Afinal Do m Aoriginal [0.8+1.2In (Agriginal)] Max Draft ho-h= MR