MAT6519

4 questions, answer 2 from 4

1 hour


Q1

i) describe the main differences between direct and indirect extrusion (4
marks)
ii) Why do we generally see a rise in extrusion pressure at the end of the
extrusion cycle ? (2 marks)
iii) an extrusion company wishes to use an indirect extrusion press with a
maximum capacity of 700 MPa to extrude an aluminium billet of
100mm diameter to a rod of 20mm diameter at temperature of 450 C.
Calculate whether the following extrusion route is feasible given that

the flow stress of the material at 450C is 120 MPa
the extrusion constants a and b are 0.8 and 1.8 respectively

and suggest any improvements or changes to the process route if
necessary (10 marks)
iv) explain why recrystallisation of the surface layers is sometimes
observed on extruded samples (4 marks)

Q2

Gauge control is one of the most important parts of any rolling process and is
vital in ensuring that the final component is of the correct dimensions

a) Discuss in detail the advantages and disadvantages of hot and cold rolling in
relation to the rolling of aluminium. (10 marks)
a) Define the term mill spring (2 marks)
a) Describe the solutions that can be put in place to ensure that variations in
starting plate thickness dont result in variations in final plate thickness (4
marks)
a) Describe the defects that can form if we try and reduce the thickness of the
material by a) too much in one pass and b) too little (4 marks)




Q3

Reducing the grain size of steels generally increases strength and allows lower
carbon steels to be used for structural applications, which in turn reduces
problems associated with ductile to brittle transition temperature and
weldability. The usual way of reducing the grain size involves a normalizing step,
which is expensive and is not effective for some grades of steel. Explain in detail
with reference to the metallurgy of the steel a method of reducing the grain size
that does not involve normalizing. (20 marks)

Q4

Avoiding or minimizing the formation of defects, either internal or surface, is
very important during any metals processing operation.

i) Explain why the quality of the starting material plays an important
role in avoiding defects during steel wire drawing (4 marks)
ii) List the three main contributions to work done during the wire
drawing process (3 marks)
iii) What defects can occur if the wrong die angle is used in wire drawing
? (3 marks)
iv) Calculate the optimum approach angle when a circular wire of 10mm
is reduced in one step to a diameter of 6mm. The friction coefficient in
this case is taken to be 0.2 (4 marks)
v) Limit diagrams can be used to provide a process window and to allow
us to choose the correct process parameters. From the data given
below, construct a limit diagram for the extrusion of aluminium (6
marks)

Billet Temperature of 350C
Ram
speed(mm/s)
Strain rate
(/s)
Extrusion
Pressure
(MPa)
Exit
Temperature
C
5 0.5 486 487
7.5 1.0 520 496
15 2.5 568 510
30 5 608 520

Billet Temperature of 400C
Ram
speed(mm/s)
Strain rate
(/s)
Extrusion
Pressure
(MPa)
Exit
Temperature
C
5 0.5 375 505
7.5 1.0 405 515
15 2.5 450 525
30 5 455 535

Billet Temperature of 450C
Ram
speed(mm/s)
Strain rate
(/s)
Extrusion
Pressure
(MPa)
Exit
Temperature
C
5 0.5 291 530
7.5 1.0 320 541
15 2.5 365 551
30 5 390 553

Billet Temperature of 500C
Ram
speed(mm/s)
Strain rate
(/s)
Extrusion
Pressure
(MPa)
Exit
Temperature
C
5 0.5 230 565
7.5 1.0 254 572
15 2.5 291 583
30 5 320 592


Additional data :

Maximum press capacity = 500 MPa
Value of lowest melting point phase in alloy = 550C