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Reg-"0-=lsl I111 ‘l~'V‘ [Ll ll

‘Question Paper Code £17115]

M.E. DEGREE EXAMINATION, NOVEMBER./DECEMBER 2016.

Second Semester

Manufacturing Engineering

MF 1203 - THEORY OF METAL FORMING \

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(Regulations 2013) of
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Time : Three hours Maximum : 100 fie

Answer ALL questions. éfi

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l PART A -— (10 x 2 = 20 marks) 3 -
1. State the main advantages of true stress-strain diagram.
2. Define Stress Tensor. n
3. State the condition for biting of strip by rolls.
4. Under what circumstances is indirect extrusion preferable to direct extrusion?
5. What are the formability tests for sheet metal?
6. Define stretch forming. www_‘aB|\ pa_c°m
7. What is the effect of residual stresses in forging? l "‘
8. State the applications of hydrostatic extrusion?
9. What types of surface treatment are used in drawing?
10. What are the important variables for duplex and triplex steel rolling process?

PART B —- (5 >< 13 = 65 marks) ‘

11. (a) What do you understand by yield criteria? Explain the two yield criteria’s
commonly used? (13)

Or
(b) For s stress state in which the intermediate stress is 0', =0.5(a, + 0-,).
Show that in yielding with a von Mises criterion and flow stress. 0', , the
diameter of the Mohr circle of Stress is (2rJ§ ) 6,. ' (13) '
12. (a) The following data pairs (load kN; extension mm) were obtained from the
plastic Part of a load-extension file for a l.€l"lFl1lB test on an extra deep
drawing quality steel sheet of 0.8 mm thickness. The initial test-Piece
width was 12.5 mm and the gauge length 50 mm-
1.57, 0.080; 1.90, 0.760: 2.24, 1.85; 2.57, 3.66; 2.78, 5.84; 2.90, 8.92
2.93, 11.06; 2.94, 13.49; 2.92, 16.59; 2.86, 19.48; 2.61, 21.82; 2-13. 22-59
Obtain engineering stress-strain, true stress, strain and log Btl'e59- 1_°B
strain curves. From these determine: initial yield stress, ultimate tensile
strength, true strain at maximum load, total elongation and the strength
coefficient, K and strain-hardening index, n. (13)
Or
~ (bl (i) Determine the various rolling defects and remedies with "eat
sketch. i (4)
(ii) Determine the rolling pressure distribution in strip rolling P1‘°°°59
with neat sketch. (9)

13. (a) In a tube hydro forming process, _a square section was Formed from a
circular tube. The initial tube had a radius of R The current corner
radius is r. The maximum thickness along the tube was 1,. The 0011191‘
thickness was 1,. The material strain-hai-dens according to the rein!‘-iOI1
U = K(1:o + ¢:)n .

Assuming that the thickness varies linearly along the tube wall, calculate
the average Friction coefficient between the tube wall and die surface.
Assume the tube just touches the die wall at the start of the process and
that there is no sticking region. (13)

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(b) Explain the working principle of water hammer forming process with
neat sketch. Write its advantages, process parameter, applications and
limitations. (13)

14. (a) (i) Explain the principle of sedimentation analysis method of particle
sizing. _, (6)
(ii) Describe the turbidimetric method of determining particle size
distribution in a Powder sample. (7)

Or ‘

(b) (i) Calculate the Force required in extruding a copper alloy at 750"C.if
billet diameter is 80 mm and the extrusion ratio is 20. (3)
(ii) Extrusion is a process involving three-dimensional Compreggionj
explain why brittle material can be worked by extrusion more
successfully than by some other metal working methods. (5)

2 in 15
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15- (a) C°mI1flI’¢ 1-he Tome required to give 9 30 per cent reduction in a 0.5-in-
diiimfifkr Wire in a 10° semi angle die with the force required to prudllflfl
the same reduction in a tube blank of 0.500 in. Outside diameter. 0.400-in.
inside diameter using a cylindrical mgndml. Assume that I = 0.08 for
both cases. (13)
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(b) (i) Explain detail about duplex and triplex roLlin8- (5)
(ii) HOW would you distinguish between the formability of difierent
heats of low carbon sheet steel? (8)

PART C - (1 x 15 =15 marks)

16. (a) Explain detail about spur gear design using powder metal1\1l'BY- ‘mat “'9
the different processes involved end of product. (15)

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(B) Explain detail about model ¢alc\fl31i0l1 involved in wind turbine blade
design. (15)

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