Mtodos de Analisis de

Procesos de Formado.

Ramrez Naranjo Jos Pablo

 Mtodos de Anlisis
13.2 The Slab Method

Table 13.1. Theoretical methods of analysis used in metal forming

Analysis results

Method Velocity field Stress field Temperature field Stresses on tooling

Uniform energy x
Slab x x
Upper-bound x x
Slip line field x x x
Finite element x x x x
Finite difference x x x x

a rod of final cross section A1 . The deformation energy required to transform this
billet into a rod can be computed by use of either eq. 4-44 or eq. 4-46 in Ch. 4. Use
of the latter yields
 340 Chapter 10 Oassical Forming Analysis

Trabajo Ideal Tensin Simple

Ideal Work in Simple Tension
To illustrate the ntethod, let's calculate the ideal work done dur
defom1ation of a rod. For the rod shown in Figure we can co
plastic work of defonnation either internally or externallyJ as
1

sf H
Llw= r- Fdl=11 - (d)2 f
! !
fJtlo 2

Wideal = Fext ds =V external

work
d =V d
intemal
plastic
internal
plastic
v..ork work
si i i

2 2
d0 d
V = l0 = l
2 2

Figure 10.1 Extension of a rod under u..'1.iaxial tension"

Mechanical principles (see Chapter 5) tell us that the intern

 () = K n

f
K
Wideal =V n
K d =V
n+1
( f i )
n+1 n+1

i
Figure 10.2 Schematic of a wireMdrawing or extrusion operation,

Trabajo Redundante
1. idea! work - minimum to accomplish the specified shape change: W,

En realidad

-
Wext =Wideal +Wfriccin +WRedundante

2. Redundant work - deformation beyond minimum required tor shape change: Wr

3. Friction work at too! surtaces: W1

Figur: 10-,3 Classification of mechanical work dissipated during forming.

 Ejemplo 1 - Tensin
Hallar el trabajo ideal, redundante y total en una operacin de
formado de 2 pasos de un barra de 10 mm x 10 mm x 100 mm.

Tensin uniaxial a una longitud de 110 mm

Compresin uniaxial a una longitud de 105 mm

Asuma que no hay trabajo de friccin y que el material obedece la

relacin de Hollomon.

= 500 0.25
[MPa ]
V = (10mm)(10mm)(100mm) =10000mm3 =105 m3

l f 105mm

f = ln = ln = 0.049
l
i
100mm

6
K n+1 50010 Pa 1+0.25
Wideal =V 5
f =10 m 3
(0.049)
n+1 1+ 0.25

Wideal = 92.2J
 1 1 +2 1 +2

Wext =W1 +W2 =V d + d =V d

0 1 0

K n+1
Wext =V (1 + 2 )
n+1

110 105
1 = ln = 0.095 2 = ln = 0.049
100 100
 K n+1
Wext =V (1 + 2 )
n+1

6
50010 Pa 0.25+1
5
Wext =10 m 3
(0.095+ 0.049)
1+ 0.25

Wext = 355J

Wredundante =Wext Wideal = 355J92.2J = 262.8J

 Eficiencia
44 Chapter 10 Classical Forming Analysis

Wideal
process,
The efficiency of a given = die materialJ machine, and so forth, m
be known from prior experienceW in order to apply the ideal work meth
ext
Typical values of efficiency are shown in Table 10.1.

'TABLE 10.1 Typical Efficiencies for Various Metalforming Operations

Uniaxial tension -1.0
Forging2 O.W-0.95
Flat rolllng 0.80-0.90
Deep drawing 0.75-0.80
Wire drawing 0.55-0.70
Extrusion 0.5-0.65

Note: It is intereSting to consider what happens to the deformation work

 wa = Fe /A0 = Pe . (6.5)

Although wa = wi for an ideal process, for an actual process wa > wi . Therefore

!
Pe > d, (6.6)

Extrusin
so equation 6.5 underestimates the extrusion work and is a lower bound to the actual
value.

chamber
D1 and A1 are the exit
diameter and area

Pe

1
D0 and A0 are the initial
diameter and area

Figure 6.1. Direct or forward extrusion.

A0 = A1 1
 wa = Fe /A0 = Pe . (6.5)

Although wa = wi for an ideal process, for an actual process wa > wi . Therefore

!
Pe > d, (6.6)
sf
! !
Wext = Fext ds = Fext
so equation 6.5 underestimates the extrusion work and is a lower bound to the actual
value.

si

chamber
D1 and A1 are the exit
diameter and area

Pe

1
D0 and A0 are the initial
diameter and area

Figure 6.1. Direct or forward extrusion.

Wext Fext
wext = = = Pe
A0 A0
 f

Pe = wext = wideal = d
0

Proceso ideal

Pe > d
0

Proceso Real
 Trefilado
78 WORK BALANCE

Wext = Fext
die
d = Fd /A1

Ao
Fext
Fd Figure 6.2. Rod or wire drawing.
A1 wext = = d
A1

> d
Wire and rod drawing (Figure 6.2) can be analyzed in a similar way. The drawing
d die. The actual work, Wa , in drawing a length,
force, Fd , pulls the metal through the
!, is Wa = Fd !, so the work per volume is 0
wa = Fd /A1 = d , (6.7)
where d is the drawing stress. Again because wa > wi ,
 Ejemplo 2 - Trefilado
El comportamiento de endurecimiento por deformacin de
una material est dado de forma aproximada por

=1400.25 [MPa ]

Encontrar el trabajo ideal por unidad de volumen, si una barra

del material se reduce de un dimetro de 12.7 a 11.5 mm en
dimetro.

Hallar el esfuerzo de trefilado, suponiendo un proceso ideal y

una eficiencia del 70 %.



 2
Ai f di f
Ai i = Af f = =
Af i d f i

f f
K n+1
d = wideal = d = n
K d =
0 0
n+1

2
f d d
= ln = ln i = 2ln i
i d f d f
 12.7
= 2ln = 0.199
11.5

K n+1 wideal wideal

d = wideal = = wext =
n+1 wext

140MPa MJ
=14.88MPa 3
0.25+1
d = wideal = (0.199)
0.25+1 m

14.88 MJ
wext = = 21.25MPa 3
0.70 m
Forja (Ensayo de compresin sin friccin)

Laminacin (Deformacin plana en

compresin sin friccin)
f

w =Ym 1
Ym =
f i
d
i

Ym
d = 0 + 1
Ym =
2
Reduccin mxima en trefilado
d,ideal K
= n+1 UTS n = (Inestabilidad Plastica)
(n+1)

Knn+1
Knn n (n+1)
(n+1)

d
2ln i (n+1)
d f

di (n+1)
exp
df
2
ne-Strain Extrusion or Drawing
The vvire-drawing or extrusion case has one simplification because of the
similarity to a tensile test, namely, that the ideal effective strain is equal to the
Extrusin de una lamina
axial strain. For other we must find the effective strain based on a
given yield surface for the ideal deformation in order to compute the ideal work.

i:=input
o:=output
T
l

Restriccin: = 0
Figure 10.4 Sche-matic of plane-strain
3 drawing operation.

Consider a extrusion or drawing operation, as shown in Figure

10.4. The only difference between this geometry and the wire-draw or extrusion
 f

No es vlido usar w = d
i
f

Entonces w = d
matic of plane-strain drawing
i operation.

extrusion ordrawing1 + 2 + 3 = 0 1 = 2
operation, as shown in Figure
ference between this geometry and the wire-draw or extrusion
al constraint; that is, there is no deformation in thex3 direction. 1
2 2 the 2
2
= (1 + 2 ) three
he volume is constant, 1 "" -t2, we can calculate
and the effective strain (as always, assuming 3 a proportional

ti
e ideal work,and = von Mlses material):
ln t = 1
2
a
o
2 2 ti
= 2 = ln
3 3 to
 Ejemplo 3 Extrusin de una lamina
Determinar la presin de extrusin Pe de una lamina de grosor inicial
igual a 0.25 que se reduce a 0.15 con una eficiencia del 75 %.

Asuma que el material sigue una relacin de tipo Hollomon con k y n

iguales a 50000 psi y 0.25 respectivamente.

f
wideal 1 K
Pe = = K d =
n
n+1
0 (n+1)

2 ti 2 ti
= ln = ln = 0.59
3 to 3 to
 K
Pe = n+1
(n+1)

50000psi 0.25+1
Pe = (0.59) = 27600psi
0.75(0.25+1)
 Mtodo de Bloques
El material se divide en bloques delgados.

Se realiza un balance de fuerzas en cada bloque.

Suposiciones
Los ejes principales coinciden con la direccin de aplicacin
de las fuerzas sobre el material.

La friccin no cambia la direccin de los ejes principales y no

causa distorsin interna en el material (Def. Homognea).
86 Trefilado de una lamina
SLAB ANALYSIS

z
w
dx
F

to
te slab

F
d =
te w7.1. Plane-strain drawing of a sheet.
Figure

dx
P
Figure 7.1. Plane-strain drawing of a sheet.
86 SLAB ANALYSIS

dx
P
dt/2 y
P

t x
t+dt
x x+dx z
Pds Pcosds

Pds
F
P ds
dx = dscos
P
dx te
Figure 7.2. Slab used for force balance in sheet drawing.

(x + dx )(t + dt)w xtw + 2Pw sinds + 2wPcosds = 0

To integrate equation 7.4, the relation between P and x must
Figure be found and
7.1. Plane-strain drawing o
substituted. The fact that P does not act in a direction normal to x will be ignored and P
will be taken as a principal stress, P = y . For yielding in plane strain, x y = 2k,
(xk +
where is
d
the )(t +strength
xyield dt)w in shear.
+ 2Pw
x tw For tandx
Tresca 2k = Y
+ 2wPdx
and for von
=dx0 2k =
Mises

(2/ 3)Y . Substituting P = 2k x into equation 7.4 P
dt/2
P
dx dt
= . (7.5)
 P
dt/2
P

Figure 7.1. Plane-strain

t + drawing
dt of atandx
td + 2P sheet. + 2Pdx = 0
x x
t+dt
x x+dx
dx Pds Pcosds
P
dt/2
P Pds

P ds
P
dx

t
t+dt
Figure 7.2. Slab used for force balance in sheet drawing.
x dt dt x+dx
tan = dx =
2dx 2tan Pds Pcosds

To integrate equation 7.4, the relation between P and x must

Pds
substituted. The
xdt +fact
tdthat + P does
Pdt + not act in a=
Pcotdt direction
0 normal to x will be
x
will be takenPas a principal stress, P = y . For yielding in plane strain,
ds
where
P k is the yield strength in shear.
dx

For Tresca 2k = Y and for vo
(2/ 3)Y . Substituting P = 2k x into equation 7.4
Figure 7.2. Slab used for force balance in sheet drawing.
 tdx + (x + P (1+ cot))dt = 0

dx dt
=
(x + P(1+ cot)) t

Por hipotesis P = 2
(aunque puede demostrarse que no es mala aproximacin)
x = 1

d1 dt
=
2 (1+ cot)1 t
 d1 dt
=
2 (1+ cot)1 t

Es una ecuacin diferencial con dos funciones 1 y 2 !

Ecuaciones de Levy-Mises (Dieter 90-91)

d 1
d3 = 3 (1 + 2 ) = 0
2

1 + 2
3 =
2
 1
1
( 1 2 ) + (2 3 ) + (3 1 ) 2
2 2
=
2

3 3
= 2 1 = (1 2 )
2 2

2
2 = 1
3
 d1 dt
=
2 t
1 (1+ cot)1
3

2
cot = B =H
3

d1 dt
=
(1 H)(1+B)1 t

d1 dt
=
1BH(1+B) t
 Condiciones de frontera

(t = t0 ) = 0
(t = te ) = d

d te
d1 dt
=
1BH(1+B) t t
0 0

1 dBH(1+B) te

ln = ln t
B H(1+B) 0
1 Bd H(1+B) te

ln = ln t
B H(1+B) 0

B
H(1+B) te
d = 1
B t0

con

2
cot = B =H
3
 Hallamos el campo de esfuerzos

H(1+B) t
B

(t ) = 1
B t0

Y la presin sobre las herramientas.

H(1+B) t
B

2 (t) = 1 H
B t0

B
(1+B) t
P (t) = H 1 1
B t0

 to
te slab

Trelado de una barra

86
Figure 7.1. Plane-strain drawing of a sheet. (Mtodo
SLAB ANALYSIS

P
dx numrico)
dt/2 y
P

t x
t+dt
x x+dx
Pds Pcosds z

Pds

P
F
dx = dscos
ds
P
dx

Figure 7.2. Slab used for force balance in sheet drawing.

2 te
(x + dx )(t + dt) x t 2
+ Pt tandx + Ptdx = 0
4 7.4, the relation 4between P and x must be found and
To integrate equation
substituted. The fact that P does not act in a direction normal to x will be ignored and P
will be taken as a principal stress, P = y . For yielding in plane strain, x y = 2k,
Figure 7.1. Plane-strain drawing o
where
k is the yield x dt
2strength+ shear. +
intd
x
For4PTresca 2k = Y +
tandx and4pdx
for von =
Mises0 2k =
(2/ 3)Y . Substituting P = 2k x into equation 7.4

dx dt dx
= . (7.5)
 P
dt/2
P

Figure 7.1. Plane-strain

2 tdt +drawing
td + of
4Patandx
sheet. + 4pdx = 0
x x
t+dt
x x+dx
dx Pds Pcosds
P
dt/2
P Pds

P ds
P
dx

t
t+dt
Figure 7.2. Slab used for force balance in sheet drawing.
x dt dt x+dx
tan = dx =
2dx 2tan Pds Pcosds

To integrate equation 7.4, the relation between P and x must

Pds
substituted. The fact that P does not act in a direction normal to x will be
2xdt + tdx + 2Pdt + 2pcotdt = 0
will be takenPas a principal stress, P = y . For yielding in plane strain,
ds
where
P k is the yield strength in shear.
dx

For Tresca 2k = Y and for vo
(2/ 3)Y . Substituting P = 2k x into equation 7.4
Figure 7.2. Slab used for force balance in sheet drawing.
 2xdt + tdx + 2Pdt + 2Pcotdt = 0

t diametro
tdx + 2(x + P + Pcot)dt = 0 r= =
2 2

rdx + 2(x + P (1+ cot))dr = 0

Del criterio de Tresca

1 = x 1 + P =Y

P =Y 1
 rd1 + 2(1 + P (1+ cot))dr = 0

P =Y 1 cot = B

rd1 + 2(1 + (Y 1 )(1+ cot))dr = 0

rd1 + 2(Y (1+ cot)1cot)dr = 0

dr
d1 = (21cot2Y (1+ cot))
r

dr
d1 = (2B1 2Y (1+B))
r
 dr
d1 = (2B1 2Y (1+B))
r

dr
d1 = F (1 )G(r)
r

F (1 ) = 2B1 G(r) = 2Y (1+B) B = cot

 Porqu G(r)?

Y = K n

1 + 2 + 3 = 0 22 = 23 = 1

1
2 2 2
r
= (1 + 2 + 3 ) = 1 = 22 = 2ln
2
2
3 r0

n
r

Y = K 2ln
r
0
 dr
d1 = F (1 )G(r)
r

F (1 ) = 2B1 G(r) = 2Y (1+B) B = cot

i
r
1i = F (1i1 )G(r i1 ) i
r

r i
r i1

i = i1 + F (1i1 )G(r i1 )
r i

(r = r0 ) = 0
 Ejemplo 4
Calcular el esfuerzo de trefilado en una barra que
se reduce de 1.0 mm a 0.6 mm en radio, fabricada
un material de que sigue una ley tipo Hollomon
con constantes K y n iguales a 500 MPa y 0.20
respectivamente.

El coeficiente de friccin de 0.3 y el ngulo de 30.

Calcular el esfuerzo de trefilado ideal.

 0.6
= 2ln =1.022
1

500MPa MJ
= 428MPa 3
0.20+1
d = wideal = (1.022)
0.20+1 m

F (1 ) = 2B1 G(r) = 2Y (1+B) B = cot

0.20
r
F (1 ) =1.03921
G(r) =1519.61522ln B = 0.5196
r
0
Python 3.5
La solucin converge a

516 MPa

wext = 516 > wideal = 428

(MPa)