NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

FACULTY OF ENGINEERING

DEPARTMENT OF INDUSTRIAL AND MANUFACTURING

ENGINEERING (PARALLEL)

NAME PHILLIP

SURNAME CHIRONGWE

STUDENT NUMBER N0174147G

COURSE MANUFACTURING PROCESSES II

COURSE CODE TIE 3213

LECTURER MR MAPINDU

ASSIGNMENT 4
QUESTION ONE
A continuous hot rolling mill has eight stands. The dimensions of the starting slab are: thickness
= 3.0 in, width = 15.0 in, and length = 10 ft. The final thickness is to be 0.3 in. Roll diameter at
each stand = 36 in, and rotational speed at stand number 1= 30 rev/min. It is observed that the
speed of the slab entering stand 1= 240 ft/min. Assume that no widening of the slab occurs
during the rolling sequence. Percent reduction in thickness is to be equal at all stands, and it is
assumed that the forward slip will be equal at each stand. Determine

(a) Percentage reduction at each stand, (b) rotational speed of the rolls at stands 2 through 8, and
(c) forward slip. (d) What is the draft at stands 1 and 8? (e) What is the length and exit speed of
the final strip exiting stand 8? [30]

SOLUTION

(a) Given that thickness = 3.0 in and final thickness is to be 0.3 in:

To reduce from t0 = 3.0 to tf = 0.3 over 8 stands,

3.0(1 - x)8 = 0.3

0.3
(1 - x)8 = = 0.10
3.0

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(1 - x) = (0.10 ¿ ¿ 8 = 0.74989

x = 1 - 0.74989 = 0.25011
r = 0.2501 = 25.01% at each stand.
(v f – v r )
(b) Forward slip S=
vr

Svr = vf – vr

(1 + s)vr = vf

At stand 1: (1 + s)vr1 = v1, where vr1 = roll speed, v1 = exit speed of slab.

At stand 2: (1 + s)vr2 = v2 , where vr2 = roll speed, v2 = exit speed of slab.

Etc.

At stand 8: (1 + s)vr8 = v8, where vr8 = roll speed, v8 = exit speed of slab.

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By constant volume, t0 w0 v0 = t1 w1 v1 = t2 w2 v2 = . . . = t8 w8 v8

Since there is no change in width, w0 = w1 = w2 = . . . w8

Therefore, t0 v0 = t1 v1 = t2 v2 = . . . = t8 v8

t0 = 3.0,

3v0 = 3(1 - r)v1 = 3(1 - r)2v2 = . . . 3(1 - r)8v8 , where r = 0.2501 as determined in part (a).

Since s is a constant, vr1 : vr1 : . . . : vr8 = v1 : v2 : . . . : v8

Given that Nr1 = 30 rev/min, vr1 = πDNr1 = (2π x 18/12)(30) = 282.78 ft/min (Taking into
account that D is in inches and vr1 in ft/min: so inches are converted).

In general Nr = (30/282.78) = 0.10609vr

Nr2 = 0.10609 x 282.78/(1-r) = 0.10609 x 282.78/(1-0.2501) = 40 rev/min
Nr3 = 0.10609 x 282.78/(1-r)2 = 53.3 rev/min
Nr4 = 0.10609 x 282.78/(1-r)3 = 71.1 rev/min
Nr5 = 0.10609 x 282.78/(1-r)4 = 94.9 rev/min

Nr6 = 0.10609 x 282.78/(1-r)5 = 126.9.3 rev/min

Nr7 = 0.10609 x 282.78/(1-r)6 = 168.5 rev/min
Nr8 = 0.10609 x 282.78/(1-r)7 = 224.9 rev/min

(c.) Given v0 = 240 ft/min

V1 = 240/(1-r) = 240/0.74989 = 320 ft/min

V2 = 320/0.74989 = 426.8 ft/min

From equations for forward slip, (1 + s)vr1 = v1

(1 + s)(282.78) = 320

(1 + s) = 320/282.78 = 1.132

s = 0.132

Check with stand 2: given v2 = 426.8 ft/min from above

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Nr2 = 0.10609vr2

Rearranging, vr2 = Nr2/0.10609 = 9.426Nr2 = 0.426(40) = 377.04 ft/min

(1 + s)(377.04) = 426.8

(1 + s) = 426.8/377.14 = 1.132

s = 0.132, as before

(d) Draft at stand 1: d1 = 3.0(0.2501) = 0.7503 in

Draft at stand 8: d8 = 3.0(1 - 0.2501)7(0.2501) = 0.10006 in

(e) Length of final strip Lf = L8

t0 w0 L0 = t8 w8 L8

Given that w0 = w8, t0 L0 = t8 L8

3.0(10 ft) = 0.3L8

L8 = 100 ft

t0 w0 v0 = t8 w8 v8

t0 v0 = t8 v8

v8 = 240(3/0.3) = 2400 ft/min

QUESTION TWO

A cold heading operation is performed to produce the head on a steel nail. The strength
coefficient for this steel is 600 MPa, and the strain-hardening exponent is 0.22. Coefficient of
friction at the die–work interface is 0.14. The wire stock out of which the nail is made is 5.00
mm in diameter. The head is to have a diameter of 9.5 mm and a thickness of 1.6 mm. The final
length of the nail is 120 mm. (a) what length of stock must project out of the die in order to
provide sufficient volume of material for this upsetting operation? (b) Compute the maximum
force that the punch must apply to form the head in this open-die operation. [20]

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SOLUTION

(a) Volume of nail head V = ΠDf2hf/4 = π(9.5)2(1.6)/4 = 113.4 mm3.

A0 = πD02/4 = π(4.75)2/4 = 19.6 mm2

h0 = V/A0 = 113.4/19.6 = 5.78 mm

(b) ε = ln(5.78/1.6) = ln 3.61= 1.2837

Yf = Kε n

Yf = 600(1.2837)0.22 = 634 MPa

Af = πDf2/4

Af = π(9.5)2/4 = 70.9 mm2

0.4 μD
Kf = 1 +
h

Kf = 1 + 0.4(0.14)(9.5/1.6) = 1.33

F = KfYfA

F = 1.33(634) (70.9) = 59886 N

QUESTION THREE

As a consulting engineer working a client whose extrusion process workshop is experiencing

various types of defects:
· Give a comprehensive account of the various possible defects that the client can possibly
experience. In your account include how these defects are caused.

· Outline how you will troubleshoot the problem that is causing the defects in this
company. Include calculations and any other problem solving methods that will help you
determine the root cause of these defects.

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 · Give engineering recommendations to your client that will help in solving the problem
[50].
SOLUTION
Owing to the considerable deformation associated with extrusion operations, a number of defects
can occur in extruded products. The defects can be classified into the following categories,

(a) Centerburst: This defect is an internal crack that develops as a result of tensile stresses along
the centerline of the workpart during extrusion. Although tensile stresses may seem unlikely in a
compression process such as extrusion, they tend to occur under conditions that cause large
deformation in the regions of the work away from the central axis. The significant material
movement in these outer regions stretches the material along the center of the work. If stresses
are great enough, bursting occurs. Conditions that promote centerburst are high die angles, low
extrusion ratios, and impurities in the work metal that serve as starting points for crack defects.
The difficult aspect of centerburst is its detection. It is an internal defect that is usually not
noticeable by visual observation. Other names sometimes used for this defect include arrowhead
fracture, center cracking, and chevron cracking. It can occur at low extrusion ratio due to low
frictional conditions on the zone of deformation at the extrusion die, (Akhtar, 2015).

Figure 1: Centerburst

Cause: Low extrusion ratios and low friction in the deformation zone at the die.

Extrusion or reduction ratio: rx = Ao/Af = Do2/Df2

Remedy: Increasing the friction at tool-billet interface to obtain a sound product

Lowering the die angle

Minimize extrusion ratio to reduce cracks

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• High friction (at the tool-billet interface) a sound product.
• Low friction centre burst.

In fact, extrusion is not a frictionless process, the effect of friction is to increase the strain
experienced by the metal. Various methods have been suggested to calculate the actual true
strain and associated ram pressure in extrusion. The following empirical equation proposed by
Johnson for estimating extrusion strain has gained considerable recognition:

ɛx = a + b ln rx

where ɛx = extrusion strain; and a and b are empirical constants for a given die angle

(b) Piping: Piping is a defect associated with direct extrusion. It is the formation of a sink hole in
the end of the billet. The use of a dummy block whose diameter is slightly less than that of the
billet helps to avoid piping. Other names given to this defect include tailpipe and fishtailing.

Figure 2: Piping
(c) Surface cracking: This defect results from high workpart temperatures that cause cracks to
develop at the surface. They often occur when extrusion speed is too high, leading to high strain
rates and associated heat generation. Other factors contributing to surface cracking are high
friction and surface chilling of high temperature billets in hot extrusion.

Figure 3: Surface cracking

Cause: i) Longitudinal tensile stresses generated as extrusion passes through the die.

ii) Very high ram speed for the given temperature.

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Remedy: Use of optimal ram speed and billet temperature and heating the container.

(d) Axial Hole/ Funnel: It is an axial hole in the back end of extrusion.

Cause: Rapid radial flow of metal during extrusion of last 1/4th of billet.

Remedy: Inclining the face of the ram at an angle to the ram axis.

(e) Inhomogeneous deformation: in direct extrusion provide the dead zone along the outer
surface of the billet due to the movement of the metal in the centre being higher than the
periphery.

• After 2/3 of the billet is extruded, the outer surface of the billet (normally with oxidised skin)
moves toward the centre and extrudes to the through the die, resulting in internal oxide stringers-
transverse section can be seen as an annular ring of oxide.

If lubricant film is carried into the interior of the extrusion along the shear bands, this will show
as longitudinal laminations in a similar way as oxide.

Solutions

· Discard the remainder of the billet (~30%) where the surface oxide begins to enter the die
· Use a follower block with a smaller diameter of the die to scalps the billet and the
oxidized layer remains in the container (in brass extrusion).

Troubleshooting for problems causing defects

Sensors will be used for this process, instruments will be wired to a processor. Prerequisites to
effective troubleshooting include good machinery instrumentation, current and historical process
data, detailed feedstock data, complete maintenance records, and operators with a good
understanding of the extrusion process. These are the important variables to monitor: melting
pressure, die temperatures, line speed, screw speed, and finished products dimensions, (Qamar,
2018).

A troubleshooting timeline is essential to help you quickly identify problems and their causes. It
records all events leading up to a process problem to help identify the cause. Constructing a
process timeline helps identify what changes in conditions upset the process. Make sure to list all
events that affects the process, (Arif & Sheikh, 2002).

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Recommendations to help solving problems
In order to solve extrusion problems you have to understand the process. So operators new to
extrusion should know instrumentation and controls, classes covering material characteristics
and machinery features. It is least effective for operators to rely on the job training alone.
Improper operation operations can cause costly damage. Corrective maintenance operations of
extrusion dies must be carried out on regular basis.

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 REFERENCES

Akhtar, S., 2015. Fatigue failure of extruded parts.. 10 ed. s.l.:J. Fail. .

Arif & Sheikh, 2002. product defects in aluminium extrusion.. 6 ed. s.l.:s.n.

Qamar, S., 2018. optimun heat treatment of extrusion die steel. s.l.:s.n.