1. The following topics will be considered in the manufacturing section of this module during the spring term:

Fundamentals of Metal Forming:
3.1 Introduction to metal forming
3.2.1 Material Properties - laws governing metal flow, hot and cold working
3.2.4 Friction between workpiece and tools
3.4.1 Forging
3.4.4b Wire drawing: Pressure on the die and axisymmetric yielding
Plane strain yielding

3.4.5 Sheet metal processing

Diagrams / Notes on Single Point Metal Cutting. pass word protected.

2.1 Single Point Cutting - Introduction - click here
2.2 Cutting geometry Only the diagram at the top of this page is needed
2.3 Cutting forces, 2.4 Theories, 2.5 Calculations, machinability
2.6 Cutting Tools - Introduction
2.7 Cutting tool materials and Tool Lives.

v) Joining Processes: welding and brazing.

2. Formulae to be remembered for MFMT 201 exam, Manufacturing Processes section.

3. Laboratory Sessions
Axisymmetric Compression of an Aluminium Cylinder - Strain Hardening of Aluminium
This will be done in the Structures Laboratory - Room 1, Smeaton Building at the University of Plymouth.

Equipment You will be given a short cylinder of aluminium which you will compress axially using the Instron machine (which has a capacity of 100,000N).

Method: Using a vernier, measure the height and diameter of the cylinder. Set the machine cross head to a nominal speed of 1 mm/minute (it appears in practice to be rather slower than the nominal setting). Set the load range to the maximum (100kN).

Carry out a hardness test on one end of the cylinder and from this determine the UTS of the aluminium.

1) Apply some grease to the ends of the cylinder and place the upright cylinder between the platens and move the cross head till it is almost in contact with the top of the cylinder. Start the cross head moving and as soon as the indicator on the chart starts to move start the stopwatch After one minute stop the watch and the machine. Remove the cylinder and measure its height and diameter.

2.) Repeat procedure 1. Check the cylinder diameter for uniformity, if the middle starts barrelling, note the maximum diameter as well as the diameter of the ends. Continue with the procedure 1 until the capacity of the machine is reached.

Results to be Calculated
You are to calculate the natural stain and true stress at each load increment. Plot a curve so that you are able to determine the values of K and n in the equation: flow stress = K(strain)ⁿ

Take ln of the true stress and ln of the true strain and plot a graph with the ln(true stress) on the vertical axis and ln(true strain) on the horizontal axis. If you use Excel then you can fit a trend line to the graph. From the graph determine K and n.

Comment on the coefficient of friction between the platens and the cylinder - by using the barrelling measurements.

Comment on the accuracy of the experiment and how the flow stress relates to the yield strength of the aluminium.

What do the results tell you about the formability of this particular aluminium?

This is carried out in Lab Smeaton 001 in the 13.00 - 15.00 slots on the following Wednesdays:
21st January 2009... Family names starting with....A to F
4th February... Family names starting with....G to M
18th February... Family names starting with....N to R
4th March... Family names starting with....S to Z

Assignment due in on Thursday 2nd April 2009 by 12.00.

4. Tutorial Questions - (Additional questions can be accessed from the MFRG 317 www pages.)
Click here

5. References
1. 'Metals Handbook', ASM, 2nd, Desk ed., 1998.
2. 'Introduction to Manufacturing Processes', J A Schey, McGraw-Hill Int. Eds., 1987.
3. 'Manufacturing Engineering and Technology', S Kalpakjian and S R Schmid, Prentice Hall Int., 2001.
4. 'Manufacturing Processes and Equipment', G Tlusty, Prentice Hall, 2000.
5. 'Mechanical Metallurgy', G E Dieter, McGraw-Hill, Int. Student Ed., 1988.
6. 'An Introduction to the Principles of Metalworking', G W Rowe, E Arnold, 1965.
7. 'Metal Machining', T Childs et. al., Butterworth-Heinemann, 2000.

David Grieve, 24th March 2009.