ndamentals of metalworking

1. 1. Chapter 1 Fundamentals of metalworking Subjects of interest Introduction/objectives

Classification of metal processes Mechanics of metalworking Flow curves Effects
of temperature on metalworking - Hot working - Cold working Effects of metallurgical
structure on forming processes Effects of speed of deformation on forming processes
Effects of friction and lubricantSuranaree University of Technology Tapany Udomphol
Jan-Mar 2007
2. 2. Objectives This chapter provides classification of metal forming processes based on
types of forces applied onto metals. Mechanics of metal forming will be outlined to
understand stress criterion for plastic deformation. Differences between hot and cold
working will be highlighted and advantages-disadvantages of hot and cold working will
be given. Effects of deformation speed and friction on metal working process will be
included.Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
3. 3. Classification of metal forming processes (based on the type of force applied on to the
work piece as it is formed into shape). Direct-compression-type processes Indirect-
compression processes Tension type processes Bending processes Shearing
processesSuranaree University of Technology Tapany Udomphol Jan-Mar 2007
4. 4. Direct-compressiontype processes:the applied force is normal tothe direction of the
metal flowin compression, i.e., forgingand rolling processes. Indirect-compression type
processes:the primary forces are frequently tensile, with indirect compressiveforces
developed by the reaction of the work piece. The metal flow istherefore under the
combined stress state, i.e., extrusion, wiredrawing,tube drawing. Suranaree University of
Technology Tapany Udomphol Jan-Mar 2007
5. 5. Tension type processes:the applied force is tensile, i.e.,stretching forming. Bending
processes:the applied force involves theapplication of bending momentsto the sheet.
Shearing processes:the applied force involves theapplication of shearing forces
ofsufficient magnitude to rupture themetal in the plane of shear.Suranaree University of
Technology Tapany Udomphol Jan-Mar 2007
6. 6. Classification of metal forming by subgroups Metal forming Compressive Combined
tensile Tensile Forming by Forming by forming and compressive forming bending
shearing formingRolling Pulling through a die Stretching Bending with
JogglingOpen die forming Deep drawing Expanding linear tool Twisting
motionClosed die forming Flange forming Recessing Blanking Bending
withIndenting Spinning rotary tool CoiningPushing through a die Upset bulging
motion Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
7. 7. Mechanics of metal working Metal working occurs due to plastic deformation which
is associated with analysis of complex stress distribution. require simplification. Only
(large) plastic strain is considered while elastic strain is very small and can be neglected.
Strain hardening is often neglected. Metal is considered to be isotropic and homogeneous.
Normally plastic deformation is not uniform and also have frictions, but we need to
simplify the stress analysis in order to determine the force required to produce a given
amount of deformation to obtain a product in a required geometry.Suranaree University
of Technology Tapany Udomphol Jan-Mar 2007
8. 8. Required theory of plasticity, and for Deformation plastic deformation a constant-
volume ho h1 relationship is required. 1 + 2 + 3 = 0 Eq. 1 In metalworking,
 compressive stress and strain are predominated. If a block of initial height ho is
compressed to h1, the axial compressive strain will be: h1 dh h hFor true strain = = ln 1
= ln o , ho > h1 Eq. 2 ho h ho h1 h1 ho h1For conventional strain e= = 1 Eq. 3
ho ho Note: the calculated strain is negative compressive strains. Suranaree University of
Technology Tapany Udomphol Jan-Mar 2007
9. 9. However the convention is reversed in metalworking problems so that compressive
stresses and strains are defined as positive. Note: ec is used as strain in deformation
process. ho ho h1 h1 c = ln , ec = = 1 Eq. 4 h1 ho ho And the fractional reduction
Ao A1 (reduction of area) in metal working r= Eq. 5 Ao deformation is given by
From the constant-volume relation A1 L1 = Ao Lo A1 A1 Ao Lo r = 1 or = 1 r Ao Ao
L1 Ao 1 A1 L1 = ln = ln = ln Lo A1 1 r Eq. 6 Suranaree University of
Technology Tapany Udomphol Jan-Mar 2007