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Ch.6 Metal Forming

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Ch.6 Metal Forming

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tsmmonzer
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Zagazig University – Faculty of Engineering

2nd Year Mechanical Engineering

Production Technology 2

Chapter (6)
Fundamentals of Metal Forming

By
Dr. Ahmed Shaker
Assistant Professor-Mechanical Design and Production
Engineering Department
Dr. Mona Abou El-Wafa Megahed
Definition
Metal forming is the process in which plastic deformation is used to permanently
change the shape of metal workpieces by applying stresses that exceed the yield strength
of the metal. This is done without melting.

To do a successful forming operation , the metal must have:

• Low yield strength


• High ductility Temperature dependent properties

Ductility is increased and yield strength is reduced when work temperature is increased.
Deformation of a solid body can be classified as elastic or plastic:
Elastic deformation Plastic deformation (Plasticity)
Elastic deformation is the deformation Plastic deformation is the permanent
in which the body always returns to its distortion that occurs when a material is
original shape after removing the load subjected to stresses that exceed its yield
strength
Engineering stress-strain curve
Plastic Deformation of Metal

• Change shape of metal in solid state without


deterioration of metal properties.

• The metal must have certain ductility

• No chips are produced.

• Volume is Constant

• Modulus of Elongation =Ao/Af = Lf/Lo


Classification of metal forming processes
Rolling

Forging
Bulk deformation
processes
Extrusion

Metal forming Drawing


processes
Shearing
Sheet metal
forming Bending
processes
Deep drawing
Bulk deformation processes
• Processes characterized by significant
deformations and large shape changes
• The surface area to volume ratio of the
work is relatively small

Examples:
a) Rolling
b) Forging
c) Extrusion
d) Drawing
Sheet metal forming processes (press working processes)
• Processes performed cold on metal
sheets, strips and coils
• The surface area to volume ratio of
the work (stamping) is high

Examples:
a) Bending
b) Deep drawing
c) Shearing
Material behavior in metal forming
Why engineering stress-strain curve is mostly
used
1. Because it is almost difficult to measure the
instantaneous cross-sectional area of the test
specimen
For engineering stress and strain

𝐹 ∆𝐿
𝜎𝑒 = 𝜀𝑒 =
𝐴𝑜 𝐿𝑜
For true stress and strain

𝐹 ∆𝐿
𝜎𝑡 = 𝜀𝑡 =
𝐴 𝐿
Volume is constant in the elastic region
𝐴 𝑜 𝐿𝑜
𝐴𝐿 = 𝐴𝑜 𝐿𝑜 → A =
𝐿
𝐹 ∆𝐿 𝐿 − 𝐿𝑜 𝐿 𝐿
𝜎𝑒 = 𝜀𝑒 = = = −1 = 1 + 𝜀𝑒
𝐴𝑜 𝐿𝑜 𝐿𝑜 𝐿𝑜 𝐿𝑜
By rearranging the true stress equation
𝐹 𝐹𝐿 𝐹
𝜎𝑡 = = = 1 + 𝜀𝑒 = 𝜎𝑒 1 + 𝜀𝑒
𝐴 𝐴 𝑜 𝐿𝑜 𝐴 𝑜

Therefor, the true stress-engineering stress equation is 𝜎𝑡 = 𝜎𝑒 1 + 𝜀𝑒


𝑛
∆𝐿𝑖
𝜀𝑡 = ෍
𝐿𝑖
𝑖=1

But for large increments


𝐿
𝑑𝐿 𝐿
𝜀𝑡 = න = 𝑙𝑛
𝐿𝑜 𝐿 𝐿𝑜

𝐿 𝜀𝑡 = ln(1 + 𝜀𝑒 )
= 1 + 𝜀𝑒
𝐿𝑜
𝜺𝒕 = True strain or logarithmic strain or natural strain
In elastic region

𝜎 = 𝐸𝜀
In plastic region
𝑛
𝜎 = 𝐾𝜀
Where,
σ is the applied stress
ε is the applied strain
E is Young’s modulus of elasticity
K is strength coefficient (MPa)
Temperature dependent (Temperature↑ K,n ↓)
n is the strain hardening exponent
K and n values for selected metals

Material K (psi) K (MPa) n


Aluminum 25,000 175 0.2
Aluminum alloys 35,000 240 0.15
Copper 45,000 300 0.5
Copper alloys, Brass 100,000 700 0.35
Low carbon steel 75,000 500 0.25
Stainless steel 175,000 1200 0.4
Flow stress
It is the instantaneous value of stress required to continue deforming of material to keep it
flowing till fracture.

𝑌𝑓 = 𝐾𝜀 𝑛 𝑌𝑓 = Flow stress 𝑀𝑝𝑎 or 𝑙𝑏/𝑖𝑛2

Average flow stress (Mean stress)

𝑛
𝐾𝜀 𝑌ഥ𝑓 = Average flow stress
𝑌𝑓 =
𝑛+1 𝜀 = Maximum strain

True strain
Strain rate

It is defined as the rate at which metal is strained by forming according to a defined


value of deformation speed.
𝜀ሶ = True strain rate 𝑠𝑒𝑐 −1
𝑉 ℎ = Instantaneous height of workpiece (mm)
𝜀ሶ =
ℎ 𝑉= Deformation speed (mm/sec)

Strain rate sensitivity


It is defined as the effect of strain rate on the mechanical strength of the deformed
material .
𝑚 𝐶= Strength constant
𝑌𝑓 = 𝐶 𝜀ሶ 𝑚= Strain rate sensitivity exponent
• The value of C is determined at a strain rate of 1.0 and m is the slope of the curve at log
scale.
Effect of temperature on strain rate

(Temperature↑ C ↓)

Recrystallization Temperature

It is the temperature at which the crystal structure of the


material begin to change.
𝑇𝑅𝑒𝑐 = (0.5 − 0.75)𝑇𝑚

𝑇𝑚 is the melting temperature


Classification of metal forming processes
Forming type Conditions Advantages Disadvantages

Performed at room temperature 1. Good accuracy in 1. High force and power


(R.T) dimensions 2. Some metals are not ductile
2. Good surface finish enough to be cold formed
Cold forming 3. High strength
4. Do not require heat

R.T < T < Recrystallization 1. Low force and power 1. High cost
Warm forming Temperature 2. No need to annealing 2. More fabrication stages

T>Recrystallization 1. Low force and power 1. High cost


Temperature 2. Needs some special labor
skills
Hot forming 3. More fabrication stages
4. Bad accuracy in dimensions
5. Bad surface finish
Isothermal forming
• It is a hot forming process that attempts to maintain the workpiece at its maximum
elevated temperature throughout the entire operation.
• This is achieved by heating the die to a temperature similar to the temperature of the
starting workpiece or slightly below.
• Isothermal forming allows to avoid non-uniform deformation and cracking of the surface
• It also allows to avoid irregular flow patterns in the metal during deformation which may
lead to high residual stresses.

Metal flow patterns in extrusion


Friction in metal forming

Friction is undesirable in metal forming because :


1. It leads to high force and power consumption
2. It causes residual stresses
3. It causes rapid wear to the die
4. When the friction is high, sticking between workpiece and die occurs
Lubrication in metal forming

Lubricant functions:
1. Reduce sticking, force, power and tool wear
2. Provide better surface finish
Considerations when selecting a lubricant
1. Type of forming process
2. Work material
3. Cost
4. The composition of the lubricant

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