You are a quality control engineer at the Alief
Premier Forging Company, and one of your
jobs is to oversee the forging process.
(a) If the unknown raw billet (5 cm in
diameter) displayed a true stress and true
strain curve shown in the figure, based on
your learning in DfM, identify the most
likely material from the supplier according
to the parameters listed in the DfM lecture.
(Must show mathematical proof of your
answer.) (10 points)
True Compressive Stress (MPa)
1000-
900-
800-
700-
600-
500-
0.01
0.1
1
10
True Compressive Strain (mm/mm)
(b) Based on the data in the graph, what is the
FORCE (N) required to upset a billet to
60% of its ORIGINAL HIGHT? (Neglecting
the influence of friction and the barreling effect.) (10 points)
(c) Assuming that the final forged product is a disc washer that has a center hole without webbing,
and the final product dimension is 12 cm (OD) x 6 cm (ID) x 2 mm (height). Assuming that the
cost of raw material is $5.10/kg, determine the material cost for a forged washer.
[Hint: (1) Follow the unit in the slides, cm $\rightarrow$ mm. (2) Consider the hold for the perimeter. (3)
There is one value missing, and you need to suggest a value based on results in (a) and (b) and
provide the source of the value.] (20 points)