Manufacturing Processes Tutorial 1 Solution a) Brass tubing, labelled A.

Extrude (hot) and then cold draw b tensile drawing to reduce dia!eter. Tensile drawing !ust be done cold. "f done hot, the !aterial will be too wea# and will brea# into two during $ulling. Then cut to length. %rawing gi&es straightness. %i!ensional accurac is a $lus $oint but is not reall necessar here since the chi!es do not $la real notes. b) %ru! barrel, labelled B. 'old roll sheet down to thic#ness of (.) !!. Then shear off to si*e and wra$ round. Sea! can be +oined !echanicall (sta$le or screw) or b gas welding or s$ot welding. ,i&etting is an o&er#ill. Too thin for T"- or an arc welding $rocess. Stainless steel needs shielding fro! at!os$here when it is welded to $re&ent the chro!iu! fro! oxidising. 'an be gas welded but !ust be done with flux ($rotects weld fro! air). c) %ru! stands, labelled '. Most co!!on !ethod e!$lo ed locall is b using rollers to for! the . !! stri$s into tubes and weld the sea! b electrical resistance or inductance (Edd currents). /ast econo!ical !ethod for large0scale $roduction of tubes. "n this case, a sea!less tube is not re1uired. 2owe&er, for critical high0$erfor!ance cases (aircraft $arts, rifle barrels and ele&ators), it is i!$ortant to ha&e sea!less tubes and $i$es, $roduced b the Mannes!an (central $iercing) $rocess or the extrusion $rocess. ,ifle barrels need to be extruded and then the central bore drilled through for accurac . d) 3egs of the stands, labelled %. 'old rolling to get nice s!ooth shining surface. 3arge hot ingot is rolled to $late. Then $late is $ic#led and cleaned with acid and acetone until shining (oxide la er eli!inated). Then it is cold rolled to si*e. Since it is !ild steel, it is necessar to chro!e it for corrrosion $rotection. ' !bal (i) Blan#ed $art is larger than the die b the allowance ()( !icrons)

%ie dia!eter 4 5(( !! 0 (.() !! 4 677.7) !! Punch dia!eter 4 677.7) 0 . x ('learance of (.1) 4 677.8) !! (ii) Pierced hole is s!aller than the $unch b the allowance ()( !icrons)

Punch dia!eter 4 1( !! 9 (.() !! 4 1(.() !! %ie dia!eter 4 1(.() 9 . x ('learance of (.1) 4 1(..) !!