Question

What are 5 effects of the die angle in extrusion process has on the "OVERALL ENERGY CONSUMPTION OF THE PROCESS"? and on a second note what are 10 advantages and 10 disadvantages in terms of only "QUALITY" and "PROCESS EFFICIENCY" for each of "drilled holes" and "pierced holes"?

Answer 1

EFFECT OF die angle in extrusion process

1) heat-treated entry angles die formed mild steel enables slips and dislocation

2)The optimum die angle will balance out the more extreme friction of lower die angles with the more extreme turbulence of higher die angles, and be somewhere between the two extremes. The exact optimum die angle is difficult to determine for any metal extrusion process due to the influence of other operational factors, such as temperature and lubrication

3)geometry of the die (especially the entry angle) but however, billet’s inherent properties could induce such deformation conditions based on the hardenability of the material which is a function of energy tendency

4)a better elongation and deformation due to the precipitation and grain crystal orientation formed as a result of the cooling system and the high energy absorbed during quenching. Hence, the hardness of each extruded sample increases as the entry angle increases

5)Maximum loads needed to be applied on the alloy to respond to deformation increases with increasing die angle and this justifies why the maximum extrusion pressure for each angle follows the orderly trend

B)metal piercing-

• Piercing metal is a process used to provide holes, slots and notches with tight tolerances within sheet metal or metal componentsMetal piercing typically does not actually remove any material
• The metal piercing process relies on plastic deformation to push or pierce a hole though the steel sheet or strip
• This piercing technique can create a burr or deformed sharp edge on the lower side of the hole
• Piercing metal provides a clean cut .
• high output rates often making it a more productive method than drilling
• Excessive point pressure can lead to accelerated wear and ultimately failure
• The amount of clearance between a punch and die for piercing is governed by the thickness and strength of the work-piece material being pierced

B)

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid materials. The drill bit is usually a rotary cutting tool, often multi-point.

• 1. The universal movements of the tool head permit the drill tool located at any desired position over the stationary work piece.

  2. Possible to work on odd shaped jobs and to drill larger diameter holes.

  3. Accurate precision drilling is possible.

• HIGH PRECISION AND ACCURACY.

• REQUIRE LESS LABOR.
• ACCURATE DIMENSION CAN BE OBTAIN JUST BY KNOWING THE COORDINATES AND DISTANCE BETWEEN THE TWO REFERENCE POINTS.
• ROBUSTNESS AGAINST EXTERNAL FORCE AND ERROR ACCUMULATION
• Disadvantages
• THE COORDINATE MEASURING MACHINE ARE VERY COSTLY.  THE (CMM) ARE LESS PORTABLE.
• IF THE OPERATION SOFTWARE CRACKS DOWN IT IS DIFFICULT TO RESTART THE ENTIRE SYSTEM.
• IT NEED TO CONSTRUCT SOME FEATURE ON ITS OWN AS SOME PARTS OF THE WORK PIECE ARE UNREACHABLE BY THE PROBE