Fundamentals of Metal Forming
Fundamentals of Metal Forming
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Metal Forming
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Classification
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Roll bending. Source: Wikipedia
Figure 18.2 – Basic bulk deformation processes: (a) rolling, (b) forging, (c) extrusion, (d) drawing
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Figure 18.3 - Basic sheet metalworking operations: (a) bending, (b) drawing, (c) shearing
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Stresses in Metal Forming
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Material Properties in Metal Forming
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Bulk Deformation Processes
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Roll bending. Source: Wikipedia
Figure 18.2 – Basic bulk deformation processes: (a) rolling, (b) forging, (c) extrusion, (d) drawing
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Sheet Metalworking
• Forming and related operations performed on metal
sheets, strips, and coils
• Often
O e cacalled
ed p g because p
pressworking
ess o presses
esses pe
perform
o
these operations
– Parts are called stampings
– Usual tooling: punch and die
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Figure 18.3 - Basic sheet metalworking operations: (a) bending, (b) drawing, (c) shearing
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Material Behavior in Metal Forming
• In plastic region
region, metal's
metal s behavior is expressed by the
flow curve:
σ = Kε n
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Typical
yp Values of K and n
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Engineering Stress-Strain
F L − Lo
σe = e=
Ao Lo
where F = applied force, Ao = original c/s area of test
specimen, L = length at any point during elongation, and
Lo = original
i i l gage llength
th
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
True Stress-Strain
L
F dL L
σ = ε= = ln
A L L Lo
o
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Flow Stress
• For most metals at room temperature, strength
increases when deformed due to strain hardening
Yf = Kε n
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Average Flow Stress
_
Kε n
Yf =
1+ n
_
where Yf = average flow stress; and ε = maximum strain
during deformation process
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Temperature in Metal Forming
– Warm working
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Cold Working
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Advantages of Cold Forming vs.
Hot Working
• Better accuracy,
y, closer tolerances
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Warm Working
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Advantages of Warm Working
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Hot Working
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Why Hot Working?
• Why?
– Strength coefficient is substantially less than at room
temperature
– Strain hardening exponent is zero (theoretically)
– Ductility is significantly increased
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Advantages of Hot Working vs. Cold Working
• Workpart shape can be significantly altered
• M
Metals
t l th
thatt usually
ll ffracture
t in
i cold
ld working
ki can b
be
hot formed
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Disadvantages of Hot Working
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Strain Rate Sensitivity
– The metal should continue to flow at the same flow stress, once
that stress is reached
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
What is Strain Rate?
• Strain rate in forming is directly related to speed of
deformation v
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Evaluation of Strain Rate
• Local strain rate can reach 1000 s-1 or more for some
metal formingg operations!
p
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Effect of Strain Rate on Flow Stress
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Figure 18.5
18 5 - (a) Effect of strain rate on flow stress at an elevated work
temperature. (b) Same relationship plotted on log-log coordinates
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Strain Rate Sensitivity Equation
Yf = Cε m
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Figure 18.6 - Effect of temperature on
flow stress for a typical metal. The
constant C in Eq.
Eq (18.4),
(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
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Observations about Strain Rate Sensitivity
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Friction in Metal Forming
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Lubrication in Metal Forming
• Benefits:
– Reduced sticking, forces, power, tool wear
– Better surface finish
– Removes heat from the tooling
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.
Considerations in Choosing a Lubricant
• Type of forming process (rolling, forging, sheet metal
drawing, etc.)
• Work material
• Ease
E off application
li ti
• Cost
Adapted from Groover, M. P., 2002, “Fundamentals of Modern Manufacturing,” John Wiley & Sons, Inc.