A cold heading operation forms the head on a steel nail. The strength coefficient for the steel = 500 MPa and the strain hardening exponent = 0.22. Coefficient of friction at the die-work interface = 0.14. The diameter of the wire stock for the nail = 4.0 mm. The nail head diameter = 10 mm, and its thickness = 1.5 mm. The final length of the nail = 60 mm. (a) What length of stock must project out of the die in order to provide sufficient volume of work material for this upsetting operation? (b) Compute the maximum force that the punch must apply to form the head in this open-die operation.

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