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Metal Forming
Bulk Deformation
Sheet metalworking
Rolling processes
Bending operations
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Common terminologies
Se ifi ished product
Bloom: is the product of first breakdown of ingot and has a square cross-
section of or larger.
Slab: is the hot rolled ingot (cross sectional area > 100 cm2 and with a
width >= 2 x thickness)
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Mill product
Sheet is the product with thickness < 5 mm and width > 600mm
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Types of Deformation
Elastic Deformation
Elastic deformations of a solid are entirely
recoverable once the stress is removed. No
part of the object under stress has
undergone permanent deformation.
Before yield point.
Plastic Deformation
Deformation beyond elastic limits.
Due to slip, grain fragmentation, movement
Fig: Typical stress-strain curve for ductile material
of atoms and lattice distortion.
In the plastic region, the etal s behavior is
expressed by the flow curve:
=
where K is the strength coefficient, Mpa
= True stress
= True strain
n is the strain-hardening exponent
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For plastic deformation, a constant-volume relationship
is required.
. . + + =
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Flow Stress
The flow curve describes the stressstrain relationship in the region in which metal forming
takes place.
It indicates the flow stress of the metalthe strength property that determines forces and
power required to accomplish a particular forming operation.
Flow stress is defined as the instantaneous value of stress required to continue deforming
the material to keep the metal flo i g.
It is the yield strength of the metal as a function of strain, which can be expressed:
=
where is the flow stress, MPa.
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Problems based on Flow stress
1. The strength coefficient = 550 MPa and strain-hardening exponent = 0.22 for a
certain metal. During a forming operation, the final true strain that the metal
experiences = 0.85. Determine the flow stress at this strain and the average flow
stress that the metal experienced during the operation.
.
Solution: Flow stress = = . =
Average flow stress = =
+
Try yourself:
1. A metal has a flow curve with strength coefficient = 850 MPa and strain-hardening exponent =
0.30. A tensile specimen of the metal with gage length = 100 mm is stretched to a length = 157
mm. Determine the flow stress at the new length and the average flow stress that the metal
has been subjected to during the deformation.
2. A particular metal has a flow curve with strength coefficient =35,000 lb/in2 and strain-
hardening exponent = 0.26. A tensile specimen of the metal with gage length = 2.0 in is
stretched to a length = 3.3 in. Determine the flow stress at this new length and the average
flow stress that the metal has been subjected to during deformation.
3. In a tensile test, two pairs of values of stress and strain were measured for the specimen metal
after it had yielded: (1) true stress = 217 MPa and true strain = 0.35, and (2) true stress = 259
MPa and true strain = 0.68. Based on these data points, determine the strength coefficient
and strain-hardening exponent.
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Yield criteria
Yielding in unidirectional tension test takes place when the
stress = F/A reaches the critical value.
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Trescas Yield Criterion
In 1864, Tresca put forward his criterion saying that
plastic flo occurs he the maximum shear stress exceeds a
critical alue .
= = ; > >
. (1)
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Strain Energy
When a force is applied to a solid, it deforms. i.e. we can say that work is done on the solid,
which is proportional to the force and deformation. The work done by applied force is stored
in the solid as potential energy, which is called the strain energy.
The strain energy in the solid may not be distributed uniformly through out the solid. Stain
energy density ( )is defined as:
=
For the general 3-D case the stain energy density is expressed as
= + + + + +
If the material is elastic, then the strain energy can be completely recovered by
Unloading the body.
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The three dimensional (triaxial) stress situation.
In the three dimensional stress situation, the state of stress at a particular location is fully defined by
three principal stress , , and .
The strain energy at a particular location of the element can be segregated into three categories, namely:
(a)Total strain energy per unit volume of the stressed element, arising from the principal stresses , ,
and .
(b)Strain energy per unit volume arising from the change of volume caused by a hydrostatic stress, which
is uniform in all three directions
(c)Strain energy per unit volume arising from distortion of the element, and which can be considered as
being the difference between (a) and (b).
The relationship between three principal stresses , , and the strains in the directions of the
principal stresses are given by:
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Energy per unit volume at stress location
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von Mises' Yield Criterion
In 1913, von Mises proposed a yield criterion, stating
that
yieldi g occurs when the work of deformation per unit volume
provided by the system of stress exceeds a critical value for the
particular material.
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HOT WORKING
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Strain rate
The rate at which the metal is strained in a forming process is directly related to the speed of
deformation, v.
In many forming operations, deformation speed is equal to the velocity of the ram or other
moving element of the equipment.
strain rate is defined as:
=
where is true strain rate, m/s/m (in/sec/in), or simply s1; and h is instantaneous
height of the workpiece being deformed, m (in).
If deformation speed v is constant during the operation, strain rate will change as h changes.
At the temperatures of hot working, flow stress depends on strain rate. The effect of strain rate on
strength properties is known as strain rate sensitivity.
=
where C is the strength constant (similar but not equal to the strength coefficient in the
flow curve equation), and m is the strain rate sensitivity exponent.
A more complete expression for flow stress as a function of both strain and strain rate would be
the following:
=
where A is a strength coefficient, combining the effects of the K and C values, n is the
strain-hardening exponent and m is the strain rate sensitivity exponent.
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Rolling Process
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Types of Rolling Mills
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Contact Length (L)
Forward and Backward Slip:
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Draft
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Fundamental concept of metal rolling
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Pressure at Neutral point
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Forging Processes
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Forging of Strip
Slab Analysis
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Total Forging force per unit length of the workpiece is given as
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Forging of Disc
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Extrusion & Drawing
Processes
Dr. Shantanu Bhattacharya
Professor, Department of Mechanical Engineering
I.I.T. Kanpur
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Extrusion Process
Extrusion is a Bulk Deformation Process in which the work is forced to flow through a die
opening to produce a desired cross-sectional shape.
=
Ram pressure (Direct extrusion):
= +
Ram force (F): =
Power required: = .
V= ram velocity.
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Wire and Bar Drawing
Similar to extrusion except work is pulled through die in drawing (It is pushed through in
extrusion).
Although drawing applies tensile stress, compression also plays a significant role since metal
is squeezed as it passes through die opening
Change in size of work is usually given by area reduction (r)
:
=
True drawing strain:
= =
If the reduction is large enough, draw stress will exceed the yield strength of the exiting
metal.
For wire drawing to be successful, maximum draw stress must be less than the yield
strength of the exiting metal.
In this ideal case, the maximum possible draw stress is equal to the yield strength of the
work material.
. . =
. =
= = .
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Sheet Drawing
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Sheet
Metalworking Processes
Dr. Shantanu Bhattacharya
Professor, Department of Mechanical Engineering
I.I.T. Kanpur
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Sheet Metalworking Processes
Bending Drawing
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Analysis of Bending process
Stretching length ()
= +
= =
are lengths of the straight parts of the blank, is the
bend allowance.
Springback:
Springback is the elastic recovery leading to the increase
of the included angle when the bending pressure is
removed.
To compensate for springback two methods are
commonly used:
Overbendingthe punch angle and radius are
smaller than the final ones.
Bottomingsqueezing the part at the end of the
stroke.
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Springback:
=
is included angle of the sheet-metal part, degrees; and
is included angle of the bending tool, degrees.
Shearing is a sheet metal cutting operation along a straight line between two cut-
ting edges by means of a power shear.
Clearance
Clearance c is the distance between
the punch and die.
The correct clearance depends on
sheet-metal type and thickness t:
=
where a is the allowance (a = 0.075 for
steels and 0.060 for aluminum alloys).
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Drawing
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