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Assigment No 1

The document is an assignment submission that includes responses to two questions about bulk deformation manufacturing processes. 1) It explains direct and indirect extrusion processes and defines die angle as the angle between the die and workpiece/container. A higher die angle results in more friction while a lower angle reduces friction. 2) It discusses cold working and hot working, and how they are used depending on material properties. It also defines barreling effect in forging as non-uniform deformation, and lists factors that contribute to it such as die design, material properties, and process parameters.

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11 views5 pages

Assigment No 1

The document is an assignment submission that includes responses to two questions about bulk deformation manufacturing processes. 1) It explains direct and indirect extrusion processes and defines die angle as the angle between the die and workpiece/container. A higher die angle results in more friction while a lower angle reduces friction. 2) It discusses cold working and hot working, and how they are used depending on material properties. It also defines barreling effect in forging as non-uniform deformation, and lists factors that contribute to it such as die design, material properties, and process parameters.

Uploaded by

21jzind0186
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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IE-244 manufacturing process

ASSIGMENT NO: 1

Submitted to: DR.Tufail habib


Submitted By: zubair khan
Registration No: 21jzind 0186
Department: Industrial Engineering
Semester: 5th semester fall

University of Engineering & Technology,


Peshawar Jalozai Campus
Assignment 1: Bulk Deformation Processes
Qn.1
a. Explain the die angle in the following figure with direct and indirect

extrusion.
Answer:
Extrusion is a manufacturing process used to create objects with a fixed cross-sectional profile.
It involves forcing material through a shaped die to produce products such as rods, tubes, pipes,
and various other profiles. The material, often in the form of a billet (a cylindrical pre-formed
solid), is pushed or drawn through the die opening, shaping it according to the specifications of
the die.
There are two main types of extrusion: direct extrusion and indirect extrusion.
1. Direct Extrusion: In direct extrusion, also known as forward extrusion, the billet is
placed in a chamber and forced through the die using a ram or a screw. The material
flows in the same direction as the ram movement. This method is straightforward and
commonly used for producing simple profiles.
2. Indirect Extrusion: Indirect extrusion, also known as backward extrusion, involves the
billet being held stationary while the die assembly, including the container and the ram,
moves towards it. The material flows in the opposite direction to the movement of the
ram. Indirect extrusion allows for more complex shapes and tighter tolerances because
the billet doesn't undergo friction with the container, resulting in a better surface finish
and mechanical properties.

NOW according to question


DIE ANGLE :
The die angle in the figure is the angle between the die and the workpiece.
In direct extrusion, the die angle is the angle between the die and the workpiece.
In indirect extrusion, the die angle is the angle between the die and the container. The die
angle affects the amount of friction and redundant work in the extrusion process. A higher die
angle results in higher friction and redundant work, while a lower die angle results in lower
friction and redundant work. The optimum die angle is the angle that minimizes the amount of
friction and redundant work in the extrusion process.
Here is a black and white image of two diagrams that was sent with your message:
1. The left diagram (a) shows a cross-section of a container, die, and workpiece in an
extrusion process.
2. The right diagram (b) shows a graph of the relationship between the die angle and the
amount of friction and redundant work in the extrusion process.
The x-axis of the graph represents the die angle, while the y-axis represents the amount of
friction and redundant work. The graph shows that as we increase the die angle, both friction
and redundant work increase. However, beyond a certain point, further increases in die angle
result in diminishing returns. Therefore, there exists an optimum die angle that minimizes
friction and redundant work.

b. Discuss how bulk deformation process is achieved based on the material


behaviorand their treatment i.e. using cold working and hot working. Explain
barreling effect inforging process?
Answer:
Bulk deformation processes are used to shape metals into desired forms by applying
compressive forces. The process can be achieved through cold working or hot
working depending on the material behavior and treatment.
Cold working is performed at room temperature or slightly above it. It is used to increase the
strength and hardness of the material. Cold working can be done through processes such as
rolling, forging, extrusion, and wire drawing. The material is subjected to compressive forces
that cause plastic deformation. The process results in a reduction in the cross-sectional area of
the material, which increases its length.
Hot working is performed at high temperatures above the recrystallization temperature of the
material. It is used to reduce the strength and hardness of the material, making it easier to
deform. Hot working can be done through processes such as rolling, forging, extrusion, and
wire drawing. The material is subjected to compressive forces that cause plastic deformation.
The process results in a reduction in the cross-sectional area of the material, which increases its
length.
The barreling effect in the forging process refers to the non-uniform deformation of a
workpiece, resulting in a barrel-like shape instead of the intended uniform shape. This
phenomenon occurs when there is non-uniform distribution of material flow during the forging
operation. Typically, the center of the workpiece experiences more deformation and material
flow compared to the outer regions, leading to excessive thinning and elongation at the center.
As a result, the workpiece takes on a shape resembling a barrel, with a bulging center and
thinner edges.
Several factors can contribute to the barreling effect in forging:
1. Die Design: The design of the forging die plays a crucial role. If the die cavities are not
properly designed with appropriate contours and radii, the material may not flow
uniformly, leading to barreling.
2. Material Properties: The material's ductility, flow behavior, and mechanical properties
at the forging temperature influence how it deforms. Materials with uneven properties
can experience uneven deformation, contributing to barreling.
3. Process Parameters: Forging parameters such as temperature, pressure, and speed can
affect material flow. Incorrectly set parameters or inconsistent application of force can
lead to non-uniform deformation and the barreling effect.
4. Die Wear: Wear and tear on the forging dies can cause uneven material flow. Worn-out
dies may not exert uniform pressure on the workpiece, leading to distorted shapes.
5. Workpiece Geometry: The initial shape and size of the workpiece can influence how it
deforms. Irregularly shaped or poorly designed workpieces are more prone to the
barreling effect.
To mitigate the barreling effect, manufacturers can take several measures:
1. Optimized Die Design: Ensuring the forging dies are properly designed with suitable
contours and radii can promote more uniform material flow.
2. Proper Process Control: Monitoring and controlling forging parameters such as
temperature, pressure, and speed are crucial. Consistent application of force and heat
helps achieve uniform deformation.
3. Die Maintenance: Regular inspection and maintenance of forging dies are essential.
Well-maintained dies ensure uniform material flow and reduce the likelihood of
distortion.
4. Material Selection: Choosing materials with appropriate properties for the forging.

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