Large group of manufacturing processes in which plastic deformation is used to change the shape of metal workpieces The tool, usually called a die, applies stresses that exceed yield strength of metal The metal takes a shape determined by the geometry of the die
Yield Strength
The yield strength is the minimum stress which produces permanent plastic deformation. This is perhaps the most common material property reported for structural materials because of the ease and relative accuracy of its measurement. The yield strength is usually defined at a specific amount of plastic strain, or offset, which may vary by material and or specification. The offset is the amount that the stress-strain curve deviates from the linear elastic line. The most common offset for structural metals is 0.2%.
Ductility
Ductility is a measure of how much deformation or strain a material can withstand before breaking. The most common measure of ductility is the percentage of change in length of a tensile sample after breaking. This is generally reported as % El or percent elongation. The R.A. or reduction of area of the sample also gives some indication of ductility.
Forged products
Structural difference
2002 John Wiley & Sons, Inc. M. P. Groover, Fundamentals of Modern Manufacturing 2/e
Sheet Metalworking
Forming and related operations performed on metal sheets, strips, and coils High surface areatovolume ratio of starting metal, which distinguishes these from bulk deformation Often called pressworking because presses perform these operations Parts are called stampings Usual tooling: punch and die
Cold Working
Performed at room temperature or slightly above Many cold forming processes are important mass production operations Minimum or no machining usually required These operations are near net shape or net shape processes
Warm Working
Performed at temperatures above room temperature but below recrystallization temperature Dividing line between cold working and warm working often expressed in terms of melting point: 0.3Tm, where Tm = melting point (absolute temperature) for metal
Hot Working
Deformation at temperatures above recrystallization temperature Recrystallization temperature = about onehalf of melting point on absolute scale In practice, hot working usually performed somewhat above 0.5Tm Metal continues to soften as temperature increases above 0.5Tm, enhancing advantage of hot working above this level
where = true strain rate; and h = instantaneous height of workpiece being deformed
Figure 18.5 (a) Effect of strain rate on flow stress at an elevated work temperature. (b) Same relationship plotted on loglog coordinates
Figure 18.6 Effect of temperature on flow stress for a typical metal. The constant C in Eq. (18.4), indicated by the intersection of each plot with the vertical dashed line at strain rate = 1.0, decreases, and m (slope of each plot) increases with increasing temperature
2002 John Wiley & Sons, Inc. M. P. Groover, Fundamentals of Modern Manufacturing 2/e