Faculty of Engineering – Cairo University

Mechanical Design and Production Engineering

Two Semesters System – 4th Year
MDP 412 – Computer Aided Metal Forming

Cold Forging Extrusion Software

(CAMF2)

Submitted To
Prof. Abdallah Wifi

Eng. Mohamed H El-Moayed

Prepared by Group (1)

Name B.N FECU CU

ID ID
Anton Tamer Shafique Abdel-Sayed 12 9161271 14710020161271
Ayman Hisham Mahmoud Ahmed 13 9130367 14710020130367
Sarah Hussam Marzok El-Ganzory 15 9171149 14710020171149
Mohamed Ahmed Morsi Ahmed 23 9121095 14710020121095
Mohamed Ashraf Mohamed Osman 24 9160627 14710020160627
Mahmoud Ahmed El-Sayed Kassab 28 9170321 14710020170321
Hager Ali Mahmoud Ali 35 9171314 14710020171314

Thursday, May 27, 2021

Anton Tamer Shafique Abdel-Sayed Ayman Hisham Mahmoud Ahmed Sarah Hussam Marzok El-Ganzory

Mohamed Ahmed Morsi Ahmed Mohamed Ashraf Mohamed Osman Hager Ali Mahmoud Ali

Mahmoud Ahmed El-Sayed Kassab (Leader)

Table of Contents
Introduction ..................................................................................................................................... 1
Hand calculations (idealized) .......................................................................................................... 2
1. Can-Can .............................................................................................................................. 2
 Design ........................................................................................................................... 2
 Stock dimensions .......................................................................................................... 2
 Combined extrusion [Backward then forward] ............................................................ 2
 Backward Extrusion (assuming it happens first) ...................................................... 2
 Forward Extrusion .................................................................................................... 3
2. Rod-Rod .............................................................................................................................. 3
 Design ........................................................................................................................... 3
 Stock dimensions .......................................................................................................... 3
 Combined extrusion [Backward then forward] ............................................................ 3
 Backward Extrusion (assuming it happens first) ...................................................... 3
 Forward Extrusion .................................................................................................... 4
3. Can-Rod .............................................................................................................................. 4
 Design ........................................................................................................................... 4
 Stock dimensions .......................................................................................................... 4
 Combined extrusion [Backward then forward] ............................................................ 4
 Backward Extrusion (assuming it happens first) ...................................................... 4
 Forward Extrusion .................................................................................................... 5
Matlab software .............................................................................................................................. 5
Introduction ................................................................................................................................. 5
Program structure ........................................................................................................................ 6
 Inputs ............................................................................................................................ 6
 Outputs.......................................................................................................................... 6
 Program User Interface ................................................................................................. 6
Program Flow-chart .................................................................................................................... 7

I
 Testing the software (CAMF2) ................................................................................................. 12
Hand calculations (semi-empirical) .............................................................................................. 14
1-Can-Can ................................................................................................................................. 14
 Backward Extrusion ................................................................................................ 14
 Forward Extrusion .................................................................................................. 14
2-Rod-Rod................................................................................................................................. 15
 Backward Extrusion ................................................................................................ 15
 Forward Extrusion .................................................................................................. 15
3-Can-Rod ................................................................................................................................. 16
 Backward Extrusion ................................................................................................ 16
 Forward Extrusion .................................................................................................. 16
EXTRUCAD 4 .......................................................................................................................... 17
Conclusion .................................................................................................................................... 18
References ..................................................................................................................................... 19
Appendices .................................................................................................................................... 20
Matlab Code .............................................................................................................................. 20

II
Introduction

In recent years, the role and importance of metal forming processes in the manufacturing
industry have been continuously expanding basically because of its material and cost-effective
nature. It is further emphasized by the recent advances in tools, materials, and design, which gives
great improvements in the mechanical properties and tolerances of the products. Additionally, in
recent years metal forming develops in the direction of net-shape or near-net-shape manufacturing
to reduce the need for subsequent machining operations and to minimize the total manufacturing
cost. Therefore, in metal forming, both the process planning and the tool design represent very
important and complex tasks. The global competitiveness also requires that the manufacturing
industry – besides the skill and the experience accumulated in the shop practice – should
increasingly utilize proven techniques of Computer-Aided Engineering for rapid and cost-effective
process design and tool manufacturing. The application of various methods of Computer Aided
Engineering has become one of the most important topics in manufacturing industries.

Therefore, it is necessary to develop generic design methods based on metal forming

analysis and on systematic experimental investigation. This tendency can be obviously seen in the
development of various knowledge-based systems for designing extruded parts and for process
planning of forming processes. As in many other metal forming applications, process planning and
design of dies for Bulk-forming can benefit from a combined application of knowledge-based
systems and process modeling. Recently, many companies are applying CAD/CAM techniques
and knowledge-based expert systems to improve and partially automate die design and
manufacturing functions. [1]

Page | 1
Hand calculations (idealized)
Using material Ck 10 from table of materials φp & Kf, ,We got its power law constants:

Kf = 740.22 φp0.216

φp < 0.1 for backward extrusion

Assume η = 0.6 if Else, η = 0.7
or φp < 0.8 for forward extrusion

1. Can-Can
 Design

 Stock dimensions

𝑑𝑜 = 60𝑚𝑚 𝑑𝑝1 = 45𝑚𝑚 𝑑𝑝2 = 45𝑚𝑚

𝑦𝑏 = 35𝑚𝑚 𝑡 = 10𝑚𝑚 𝑦𝑓 = 35𝑚𝑚

𝜋 𝜋 𝜋
𝑉 = ( 𝑑0 2 ∗ 𝑡) + ( (𝑑𝑜 2 −𝑑𝑝2 2 ) ∗ 𝑦𝑓 ) + ( (𝑑𝑜 2 −𝑑𝑝1 2 ) ∗ 𝑦𝑏 ) = 114,864.48 mm3
4 4 4
114,864.48
𝑑𝑜 = 60𝑚𝑚 ℎ𝑜 = 𝜋 = 40.62𝑚𝑚
𝑥602
4

 Combined extrusion [Backward then forward]

 Backward Extrusion (assuming it happens first)
Do 60 Ap1 452 .
= = 8 < 10 (thick-walled) φp = ln ( ) = ln ( ) = 0.2513 < 1.1
s 7.5 Af 602 −452

. kφp n 740.22∗0.25130.216
K strm = = = 451.719 MPa
n+1 1.216

π 2
Ap ∗ K strm ∗ φp 4 ∗ 45 ∗ 451.719 ∗ 0.2513
F= = = 257915.66 N
η 0.7

Page | 2
  Forward Extrusion
𝐴𝑜 602
.φ𝑝 = ln (𝐴𝑓) = ln (602 −452 ) = 0.8267 < 1.2

. kφp n 740.22∗0.82670.216
K strm = = = 584.217 MPa
n+1 1.216

𝜋 2
𝐴𝑝 ∗ K 𝑠𝑡𝑟𝑚 ∗ φ𝑝 4 ∗ 45 ∗ 584.217 ∗ 0.8267
F= = = 1097334.4 N
𝜂 0.7

As F(forward) > F(backward) then the assumption is right

Machine Capacity = 1097334.4 N = 111.85 Tons

2. Rod-Rod
 Design

𝑑𝑜 = 40𝑚𝑚 𝑑𝑝1 = 28𝑚𝑚 𝑑𝑝2 = 28𝑚𝑚

𝑦𝑏 = 30𝑚𝑚 𝑡 = 40𝑚𝑚 𝑦𝑓 = 30𝑚𝑚

 Stock dimensions
𝜋 𝜋 𝜋 𝜋
.𝑉 = ( 4 𝑑0 2 ∗ 𝑡) + 2 𝑥 (4 (dp1 2 ) ∗ yb ) = ( 4 402 ∗ 40) + (2 ∗ 4 ∗ 282 ∗ 30) = 87210.61 𝑚𝑚3

87210.61
𝑑𝑜 = 40𝑚𝑚 ho = π = 69.4mm
x402
4

 Combined extrusion [Backward then forward]

 Backward Extrusion (assuming it happens first)
𝐴𝑝 402 − 282
φ𝑝 = ln ( ) = ln ( ) = 0.04 < 1.1
𝐴𝑓 282

kφp n 740.22 ∗ 0.040.216

K strm = = = 303.719 MPa
n+1 1.216
𝜋
𝐴𝑝∗K𝑠𝑡𝑟𝑚 ∗φ𝑝 ∗(402 −282 )∗303.719 ∗0.04
4
.F = = = 12976.6N
𝜂 0.6

Page | 3
  Forward Extrusion
𝐴 402
.φ𝑝 = ln (𝐴𝑜 ) = ln (282 ) = 0.7133 < 1.2
1

kφp n 740.22∗0.71330.216
.K = = = 565.892 MPa
strm n+1 1.216

𝜋
𝐴𝑝∗K𝑠𝑡𝑟𝑚 ∗φ𝑝 ∗(402 −282 )∗565.892 ∗0.7133
4
.F = = = 431156.1 N
𝜂 0.6

As F(forward) > F(backward) then the assumption is right

Machine Capacity = 431156.1 N = 43.95 Tons

3. Can-Rod
 Design

𝑑𝑜 = 60𝑚𝑚 𝑑𝑝1 = 45𝑚𝑚 𝑑𝑝2 = 45𝑚𝑚

𝑦𝑏 = 35𝑚𝑚 𝑡 = 10𝑚𝑚 𝑦𝑓 = 35𝑚𝑚

 Stock dimensions
𝜋 𝜋 𝜋
.𝑉 = (4 𝑑0 2 ∗ 𝑡) + ( 4 ∗ 𝑑𝑝2 2 ∗ 𝑦𝑓 ) + ( 4 (𝑑𝑜 2 −𝑑𝑝1 2 ) ∗ 𝑦𝑏 ) =
𝜋 𝜋 𝜋
( 4 602 ∗ 10) + ( 4 ∗ 452 ∗ 35) + ( 4 (602 −452 ) ∗ 35)=127234.5 mm3

127234.5
𝑑𝑜 = 60𝑚𝑚 ho = π = 45mm
x602
4

 Combined extrusion [Backward then forward]

 Backward Extrusion (assuming it happens first)
𝐷𝑜 60
= 7.5 = 8 < 10 (thick-walled)
𝑠

𝐴𝑝 452 kφp n 740.22∗0.25130.216

φ𝑝 = ln ( 𝐴𝑓1 ) = ln (602 −452) = 0.2513 < 1.1 .K
strm = = = 451.719 MPa
n+1 1.216

𝜋
𝐴𝑝∗K𝑠𝑡𝑟𝑚 ∗φ𝑝 ∗452 ∗451.719 ∗0.2513
4
.F = = = 257915.6 N
𝜂 0.7

Page | 4
  Forward Extrusion
𝐴𝑜 602 kφp n 740.22∗0.575360.216
.φ𝑝 = ln (𝐴𝑝 ) = ln (452 ) = .57536 < 1.2 K strm = = = 540.224 MPa
2 n+1 1.216

𝜋 2
𝐴𝑝 ∗ K 𝑠𝑡𝑟𝑚 ∗ φ𝑝 4 ∗ 45 ∗ 540.224 ∗ .57536
F= = = 823905.1 N
𝜂 0.6

As F(forward) > F(backward) then the assumption is right

Machine Capacity = 823905.1 N = 83.98 Tons

Result Stock Stock F(forward) F(backward) Machine Capacity

(diameter) (height)
Can-Can 60𝑚𝑚 40.62𝑚𝑚 1097334.4 N 257915.6 N 111.85 Tons
Rod-Rod 40𝑚𝑚 69.4mm 431156.1 N 12976.6 N 43.95 Tons
Can-Rod 60𝑚𝑚 45mm 823905.1 N 257915.6 N 83.98 Tons

Matlab software
Introduction
A Matlab code is developed on GUI to build a program that is very similar to EXTRUCAD4.
The only difference is that our program is based on ideal calculations of the 3 selected extrusion
products. But, EXTRUCAD4 is based on empirical calculations.

The main purpose of the software is to facilitate the calculations of forces and machine capacity
required to produce certain products using certain material and doing these calculations and
multiple iterations in no time.

The only assumption made is for efficiency and made based on the concept that when the strain
increases the efficiency increase, thus taking two values of efficiency for low and high strains.

φp < 0.1 for backward extrusion

Assume η = 0.6 if Else, η = 0.7
or φp < 0.8 for forward extrusion

To run the software (CAMF2) scan

the QR code and download the
program.

Page | 5
Program structure
 Inputs
The user can:

 Choose material between 5 materials [Al 99.8 - Al MgSi 1 - Ck 10 - CuZn 37 (Ms63) - Cq

15/Ck 15].
or define a new material by his own but it’s required to input {strain coefficient (k) – strain
exponent (n) – maximum strain for material – permissible strain (forward) - permissible
strain (backward)}.
 Choose the type of product he wants to [Can-Can / Rod-Rod / Can-Rod].
 Put his product dimensions [𝑑𝑜 - 𝑑𝑝 (𝑏) - 𝑑𝑝 (𝑓) - 𝑦(𝑏) - 𝑦(𝑓) – 𝑡 ] and those dimensions
are defined differently depending on the product type.

 Outputs
 [Specimen (diameter) in (mm) / Specimen (height) in (mm) / Force (forward) in (N)/
Force (backward) in (N) / Machine Capacity required in (Tons) ]
 Suggested machine configuration.

 Program User Interface

Page | 6
Program Flow-chart

Page | 7
Page | 8
Page | 9
Page | 10
Page | 11
Testing the software (CAMF2)

Can- Can calculations

Rod- Rod calculations

Page | 12
 Can- Rod calculations

Result Stock Stock F(forward) F(backward) Machine Capacity

(diameter) (height)
Can-Can 60𝑚𝑚 40.625𝑚𝑚 1097300 N 257934 N 111.85 Tons
Rod-Rod 40𝑚𝑚 69.4mm 431193 N 12978.7 N 43.95Tons
Can-Rod 60𝑚𝑚 45mm 823913N 257934 N 83.98 Tons

Page | 13
Hand calculations (semi-empirical)
Using material Ck 10 equivalent to AISI 1010 Su=400MPa Sy=250MPa

1-Can-Can
Using previous dimension 𝐷𝑜 = 60𝑚𝑚 𝐿𝑜 = 40.62𝑚𝑚 𝑑1,b = 𝑑1,f = 45𝑚

 Backward Extrusion
𝐴𝑜 𝐴 𝐿𝑜 40.62
.𝐶𝑎𝑛 𝑏𝑎𝑐𝑘𝑤𝑎𝑟𝑑: 𝑃𝑏,𝑐 = 𝑞(2.4𝑆𝑢𝑡 + 50)(𝐴 )√𝐴𝑜 − 1 as = = .677
𝑜 −𝐴1 1 𝐷𝑜 60

𝐴𝑜 −𝐴1 602 −452

= = .4375 so from graph q=1
𝐴𝑜 602

602 602
.𝑃𝑏,𝑐 = 1(2.4 ∗ 400 + 50) (602 −452) √452 − 1 = 2040.5𝑀𝑃𝑎
𝜋
𝑃∗𝐴𝑝 2040.5∗ (452 )
4
𝐹(𝑇𝑜𝑛) = 1000∗9.81 = = 330.6 𝑇𝑜𝑛
1000∗9.81

 Forward Extrusion
𝐿 40.62
.𝐶 = exp (0.19 ∗ 𝐷𝑜 − 0.15) = exp (0.19 ∗ − 0.15) = .97885
𝑜 60

𝐴
.𝑓𝑜𝑟𝑤𝑎𝑟𝑑: 𝑃𝑓 = (1124.8 ln (𝐴𝑜 ) + 304 − 𝑆𝑦 ) ∗ 𝐶 + 𝑆𝑦
1

602
= (1124.8 ln ( 2 ) + 304 − 250) ∗ .97885 + 250 = 936.344𝑀𝑃𝑎
45

𝜋
𝑃∗𝐴𝑝 936.344∗ (452 )
4
.𝐹(𝑇𝑜𝑛) = 1000∗9.81 = = 151.8 𝑇𝑜𝑛
1000∗9.81

As F(backward) > F(forward) then Machine Capacity = 330.6 Ton

Page | 14
2-Rod-Rod
Using previous dimension 𝐷𝑜 = 40𝑚𝑚 𝐿𝑜 = 69.4𝑚𝑚 𝑑1,b = 𝑑1,f = 28𝑚

 Backward Extrusion
𝐴 𝐴𝑜
.𝑅𝑜𝑑 𝑏𝑎𝑐𝑘𝑤𝑎𝑟𝑑: 𝑃𝑏,𝑟 = (1018.8 ln (𝐴𝑜 ) + 288.8)(𝐴 )
1 𝑜 −𝐴1

402 402
.= (1018.8 ln (282 ) + 288.8) (402 −282) = 1991.3 𝑀𝑃𝑎

𝜋
𝑃∗𝐴𝑝 1991.3∗ (402 −282 )
4
.𝐹(𝑇𝑜𝑛) = 1000∗9.81 = = 130 𝑇𝑜𝑛
1000∗9.81

 Forward Extrusion
𝐿 69.4
.𝐶 = exp (0.19 ∗ 𝐷𝑜 − 0.15) = exp (0.19 ∗ − 0.15) = 1.1968
𝑜 40

𝐴
.𝑓𝑜𝑟𝑤𝑎𝑟𝑑: 𝑃𝑓 = (1124.8 ln (𝐴𝑜 ) + 304 − 𝑆𝑦 ) ∗ 𝐶 + 𝑆𝑦
1

402
= (1124.8 ln ( 2 ) + 304 − 250) ∗ 1.1968 + 250 = 1211 𝑀𝑃𝑎
40 − 282

𝜋
𝑃∗𝐴𝑝 1211∗ (402 −282 )
4
𝐹(𝑇𝑜𝑛) = = = 79.1 𝑇𝑜𝑛
1000∗9.81 1000∗9.81

As F(backward) > F(forward) then Machine Capacity = 130 Ton

Page | 15
3-Can-Rod
Using previous dimension 𝐷𝑜 = 60𝑚𝑚 𝐿𝑜 = 45𝑚𝑚 𝑑1,b = 45 𝑑1,f = 28𝑚

 Backward Extrusion
𝐴𝑜 𝐴 𝐿𝑜 45
.𝐶𝑎𝑛 𝑏𝑎𝑐𝑘𝑤𝑎𝑟𝑑: 𝑃𝑏,𝑐 = 𝑞(2.4𝑆𝑢𝑡 + 50)(𝐴 )√𝐴𝑜 − 1 as = 60 = .75
𝑜 −𝐴1 1 𝐷𝑜

𝐴𝑜 −𝐴1 602 −452

= = .4375 so from graph q=1
𝐴𝑜 602

602 602
.𝑃𝑏,𝑐 = 1(2.4 ∗ 400 + 50) (602 −452) √452 − 1 = 2040.5𝑀𝑃𝑎
𝜋
𝑃∗𝐴𝑝 2040.5∗ (452 )
4
𝐹(𝑇𝑜𝑛) = 1000∗9.81 = = 330.6 𝑇𝑜𝑛
1000∗9.81

 Forward Extrusion
𝐿 45
.𝐶 = exp (0.19 ∗ 𝐷𝑜 − 0.15) = exp (0.19 ∗ 60 − 0.15) = .9925
𝑜

𝐴
.𝑓𝑜𝑟𝑤𝑎𝑟𝑑: 𝑃𝑓 = (1124.8 ln (𝐴𝑜 ) + 304 − 𝑆𝑦 ) ∗ 𝐶 + 𝑆𝑦
1

602
= (1124.8 ln ( 2 ) + 304 − 250) ∗ .9925 + 250 = 954.91 𝑀𝑃𝑎
45

𝜋
𝑃∗𝐴𝑝 954.91∗ (452 )
4
𝐹(𝑇𝑜𝑛) = 1000∗9.81 = = 153.35 𝑇𝑜𝑛
1000∗9.81

As F(backward) > F(forward) then Machine Capacity = 330.6 Ton

Result P(backward) P(forward) F(backward) F(forward) Machine

Capacity
Can-Can 2040.6𝑀𝑃𝑎 936.344𝑀𝑃𝑎 330.6 Tons 151.8 Tons 330.6 Tons
Rod-Rod 1991.3MPa 1211𝑀𝑃𝑎 130 Tons 79.1 Tons 130 Tons
Can-Rod 2040.5𝑀𝑃𝑎 954.91MPa 330.6 Tons 153.35 Tons 330.6 Tons

Page | 16
EXTRUCAD 4

Can- Can Rod- Rod

Result P(max) Machine

Capacity
Can-Can 2040.5𝑀𝑃𝑎 330.6 Tons
Rod-Rod 1991.3MPa 130 Tons
Can-Rod 2040.5𝑀𝑃𝑎 330.6 Tons

Can- Rod

Page | 17
Conclusion
By finishing the program, the previous calculations of the 3 selected products were tested
on the program and the results were identical. Also, we obtained EXTRUCAD4 results for the
same selected products and compared them to that of our program.

Applying the same products dimensions and for the same material applied (Ck 10) equivalent to
(AISI 1010) we compare the results of the machine capacity required from the hand calculations,
the Matlab software, and the EXTRUCAD4.

Result Hand calculation Matlab software Hand calculation EXTRUCAD4

idealized semi-empirical

Can-Can 111.85 Tons 111.85 Tons 330.6 Tons 330.6 Tons

Rod-Rod 43.95 Tons 43.95Tons 130 Tons 130 Tons

Can-Rod 83.98 Tons 83.98 Tons 330.6 Tons 330.6 Tons

 There is no difference between the results got from the hand calculations and from Matlab
software which verifies that the code has no error in the solving procedure.
 There is a big difference between the hand calculation and EXTROCAD4, the machine
capacity required gotten from EXTROCAD4 is approximately three times the hand
calculation machine capacity. This is because EXTROCAD4 uses empirical equation
derived by experiment and considered a lot of factors compared to the ideal case
calculations which have not.

Page | 18
References
[1] Z. L. and G. G. G. Miklós Tisza*, “Integrated Process Simulation and Die-Design,” no.
May, 2007.

Page | 19
Appendices
Matlab Code
% Variable decleration
%M [represent the material properties k,n,stalf,stalb]
%x [choosing the material]
%y [choosing the product type]
%k [Strain Coefficient]
%n [Strain Exponent]
%stalf [Permissible Strain (Forward)]
%stalb [Permissible Strain (Backward)]
%do [outer diameter]
%dpb [punch diamter (Backward)]
%dpf [punch diamter (Forkward)]
%yb [extruded height(Backward)]
%yf [extruded height(Forkward)]
%t [unextruded height]
%vold [product volume]
%H [specimen height]
%s [product extruded thickness]
%eff [effeciency]
%stb [strain calculated from backward extrusion]
%stf [strain calculated from forkward extrusion]
%kfb [mean flow stress calculated from backward strain]
%kff [mean flow stress calculated from forkward strain]
%Fb [force gotten from backward extrusion]
%Ff [force gotten from forkward extrusion]
%C [machine capacity required for extrusion]
M1 = [ 149.95 0.2218 3.9 4.5 ]; %Al 99.8
M2 = [ 259.97 0.1974 3 3.5 ]; %Al MgSi 1
M3 = [ 740.22 0.216 1.2 1.1 ]; %Ck 10 [AISI 1010]
M4 = [ 879.89 0.4327 1.2 1.1 ]; %CuZn 37 (Ms63)
M5 = [ 760.16 0.1647 1.2 1.1 ]; %Cq 15/Ck 15 [AISI 1015]
x = 3;
if x == 1
k = M1 (1,1);
n = M1 (1,2);
stalf = M1 (1,3);
stalb = M1 (1,4);
elseif x == 2
k = M2 (1,1);
n = M2 (1,2);
stalf = M2 (1,3);
stalb = M2 (1,4);
elseif x == 3
k = M3 (1,1);
n = M3 (1,2);
stalf = M3 (1,3);
stalb = M3 (1,4);
elseif x == 4
k = M4 (1,1);
n = M4 (1,2);
stalf = M4 (1,3);
stalb = M4 (1,4);
elseif x == 5
k = M5 (1,1);
n = M5 (1,2);
Page | 20
stalf = M5 (1,3);
stalb = M5 (1,4);
else
fprintf ('error');
end
y=1;
if y==1
% CAN CAN
do=60; dpb=45; dpf=45; yb=35; yf=35; t=10;
vold=(pi/4)*do^2*(yb+t+yf)-(pi/4)*dpb^2*yb-(pi/4)*dpf^2*yf;
H=vold/((pi/4)*do^2);
s=(do-dpb)/2; %Can Backward
if do/s < 10
stb=log(dpb^2/(do^2-dpb^2));
if stb > 0.1
eff=0.7;
else
eff=0.6;
end
if stb < stalb && stb>0
kfb=(k*(stb^n))/(1+n);
Fb=((pi/4)*dpb^2*kfb*stb)/eff;
else
fprintf('error in dimensions');
return;
end
else
stb=log(dpb/(do-dpb))-0.16;
if stb > 0.1
eff=0.7;
else
eff=0.6;
end
if stb < stalb && stb>0
kfb=(k*(stb^n))/(1+n);
Fb=(((pi/4)*dpb^2*kfb)/eff)*(2+0.25*(H/s));
else
fprintf('error in dimensions');
return;
end
end
stf=log(do^2/(do^2-dpf^2)); %Can Forward
if stf > 0.8
eff=0.7;
else
eff=0.6;
end
if stf < stalf && stf>0
kff=(k*(stf^n))/(1+n);
Ff=((pi/4)*dpb^2*kff*stf)/eff;
else
fprintf('error in dimensions');
return;
end
if Fb>Ff
F=Fb;
Page | 21
else
F=Ff;
end
C=F/(1000*9.81);
fprintf ('Forward force = %.2f N. \n', Fb);
fprintf ('Backward force = %.2f N. \n', Ff);
fprintf ('Machine capacity = %.2f Ton. \n', C);
fprintf ('Specimen diameter = %.2f mm. \n', do);
fprintf ('Specimen height = %.2f mm. \n', H);
elseif y==2
% ROD ROD
do=40; dpb=28; dpf=28; yb=30; yf=30; t=40;
vold=(pi/4)*do^2*t+(pi/4)*dpb^2*yb+(pi/4)*dpf^2*yf;
H=vold/((pi/4)*do^2);
stb=log((do^2-dpb^2)/dpb^2); %Rod Backward
if stb > 0.1
eff=0.7;
else
eff=0.6;
end
if stb < stalb && stb>0
kfb=(k*(stb^n))/(1+n);
Fb=((pi/4)*(do^2-dpb^2)*kfb*stb)/eff;
else
fprintf('error in dimensions');
return;
end
stf=log(do^2/(dpf^2)); %Rod Forward
if stf > 0.8
eff=0.7;
else
eff=0.6;
end
if stf < stalf && stf>0
kff=(k*(stf^n))/(1+n);
Ff=((pi/4)*(do^2-dpb^2)*kff*stf)/eff;
else
fprintf('error in dimensions');
return;
end
if Fb>Ff
F=Fb;
else
F=Ff;
end
C=F/(1000*9.81);
fprintf ('Forward force = %.2f N. \n', Fb);
fprintf ('Backward force = %.2f N. \n', Ff);
fprintf ('Machine capacity = %.2f Ton. \n', C);
fprintf ('Specimen diameter = %.2f mm. \n', do);
fprintf ('Specimen height = %.2f mm. \n', H);
elseif y==3
%CAN ROD
do=60; dpb=45; dpf=45; yb=35; yf=35; t=10;
vold=(pi/4)*do^2*(t)+(pi/4)*dpf^2*(yf)+(pi/4)*(do^2-dpb^2)*yb;
Page | 22
H=vold/((pi/4)*do^2);
s=(do-dpb)/2; %Can Backward
if do/s < 10
stb=log(dpb^2/(do^2-dpb^2));
if stb > 0.1
eff=0.7;
else
eff=0.6;
end
if stb < stalb && stb>0
kfb=(k*(stb^n))/(1+n);
Fb=((pi/4)*dpb^2*kfb*stb)/eff;
else
fprintf('error in dimensions');
return;
end
else
stb=log(dpb/(do-dpb))-0.16;
if stb > 0.1
eff=0.7;
else
eff=0.6;
end
if stb < stalb && stb>0
kfb=(k*(stb^n))/(1+n);
Fb=(((pi/4)*dpb^2*kfb)/eff)*(2+0.25*(H/s));
else
fprintf('error in dimensions');
return;
end
end
stf=log(do^2/(dpf^2)); %Rod Forward
if stf > 0.8
eff=0.7;
else
eff=0.6;
end
if stf < stalf && stf>0
kff=(k*(stf^n))/(1+n);
Ff=((pi/4)*(dpb^2)*kff*stf)/eff;
else
fprintf('error in dimensions');
return;
end
if Fb>Ff
F=Fb;
else
F=Ff;
end
C=F/(1000*9.81);
fprintf ('Forward force = %.2f N. \n', Fb);
fprintf ('Backward force = %.2f N. \n', Ff);
fprintf ('Machine capacity = %.2f Ton. \n', C);
fprintf ('Specimen diameter = %.2f mm. \n', do);
fprintf ('Specimen height = %.2f mm. \n', H);
else fprintf('error');
end

Page | 23