FORGING ANALYSIS

#Determine the sliding force of a friction hill.

It is possible to derive a mathematical expression for the friction hill by considering the forces and stresses
operating in the deformation process. Let’s consider that a case of a plain strain deformation of an open die
forging.
friction থাকায়
move হতে দেয়
না

freely move হতে

পারে

মাঝে friction নাই | inhomogeneous deformation হয়, বেশি energy লাগে (redundant work) | deformation সবচেয়ে কম centerline
বরাবর | force always uniform হয় না.

A piece of metal thickness (or height) h, width 2a, and length l is compressed between a pair of parallel
platens. According to the figure 1, the work piece is kept on lower die in stationary condition and the upper
die is allowed to move downward for applying pressure. As it keeps moving downward, the height of the
workpiece also changing due to continuous pressure.

Figure 1 Figure 2

Now, we assuming the constant volume relationship during the deformation process.

the direction of upper die. As a result, a friction force, F will develop at the interface region of the
While the height keeps on decreasing, the lateral flow of material will occur (barreling) perpendicular to

workpiece and the dies. Consider the state of the forces on a vertical element inside the metal of width dx
and distance x from the center line.
Since this element is stationary the resultant forces acting it must be zero (Figure 2).
(Q+dQ) hl – Qhl – 2F = 0
 hldQ = 2F………….(i)

Assuming that Coulomb Friction conditions operate Resisting

(this is usually theকাজ
force যেখানে case in cold working when sliding
করছে, তার cross section বিবেচনা করলে a
occurs) and μ is the coefficient of friction, the following relationship can be written
আসে না
 τfriction = μP
=¿μP
F

A
=¿μP
F

 F = dx.l.μP
dxl

2(dx.l.μP) = hldQ
value of F putting in (i)

 hdQ = 2μPdx……(ii)
The above equation can be integrated directly if the relationship between P and Q is known. This can be
found, since it is known that the element is at the point of yielding, therefore Tresca's Yield Criterion must
hold. If it is assumed that P and Q are the major and minor principal stresses for the element, then

 P-Q = σ0
 dP-dQ = dσ0
 dP = dQ [dσ =0, Where σ is the yield
0 0

stress of the metal]

 hdQ = 2μPdx
Equation (ii) can be rewritten and integrated as,

=
dQ 2 μdx

P h
 ∫ =∫
dP 2μ
dx
P h
 lnP = + c ………………(iii)
2 μx

Here c is the integration constant. Equation (iii) can be rewritten as,

h

P = c ' exp
2 μx

the value of c’ can be determined since at x=± a , and according to Von Mises yield criterion
h

P = (2/√3)σ0
= 1.115σ0 = 2k
[ plane strain condition ]

Or, P = σ0
( k= critical resisting stress)
[ homogeneous strain condition ]
Now, putting the value of P and x into equation (iii) we can rewrite as,
 lnσ0 =
2μ±a N:B: Lubricant use করলে friction কমে যায়।
+c ফলে তা plane strain থেকে homogenous
h
 c = lnσ0
এর দিকে অগ্রসর হয়।
−2 μ ± a
h
 lnP = lnσ0
−2 μx −2 μ ± a
(from iii again)
h h
 lnP−¿lnσ0 =
2μ
(x ± a)
h
 ln(P/σ0) =
2μ
(a ± x)
h
 P/σ0 = exp
2μ
(x ± a)
h
from Taylor series,

e = 1+x+ + +……………..
2 3
x x x
2! 3!
 = 1+
2 μ (x ±a) 2 μ( x ± a)
h
e h
(neglecting others)

 P/σ0= 1+
2 μ( x ± a)
h
This is the equation of friction hill due to sliding friction.

 P= σ0 + σ0
[cold work condition]
2 μ( x ± a)

For minimum value of P (at the edge) = σ0

h

Pmin = σ0
When, x=± a

When, x=0
Pmax = σ0(1+
2μa
¿
h
Now, Pmean = (Pmin+ Pmax)/2
 P= σ0 [1+
μa
¿
h
This is the final equation of friction hill. It is also called the pressure distribution equation of a cold
workpiece due to forging.

Figure: friction hill formed in forging.

FORGING ANALYSIS

#Determine the sticking force of a friction hill.

for sticking friction, μ ≥ 0.5
It is possible to derive a mathematical expression for the friction hill by considering the forces and stresses
operating in the deformation process. Let’s consider that a case of a plain strain deformation of an open die
forging.

A piece of metal thickness (or height) h, width 2a, and length l is compressed between a pair of parallel
platens. According to the figure 1, the work piece is kept on lower die in stationary condition and the upper
die is allowed to move downward for applying pressure. As it keeps moving downward, the height of the
workpiece also changing due to continuous pressure.

Figure 1 Figure 2

Now, we assuming the constant volume relationship during the deformation process.

the direction of upper die. As a result, a friction force, F will develop at the interface region of the
While the height keeps on decreasing, the lateral flow of material will occur (barreling) perpendicular to

workpiece and the dies. Consider the state of the forces on a vertical element inside the metal of width dx
and distance x from the center line.
Since this element is stationary the resultant forces acting it must be zero (Figure 2).
(Q+dQ) hl – Qhl – 2F = 0 ………….(i)
If sticking friction occurs then equation (i) must be modified, since the friction force, F 1, must equal K the

F = μ P = K = σ0/2 [where, P =
critical shear stress of the metal. Then

mean pressure]
If this submitted into equation (1) we get:

τfriction = μP
 hldQ = 2K……………(ii)
=¿μP
Now, F

=¿μP  F = dx.l.μP
F dxl

A

2(dx.l.μP) = hldQ
value of F putting in (i)

 hdQ = ±2Kdx……(iii)
[μ P = K]

The above equation can be integrated directly if the relationship between P and Q is known. This can be
found, since it is known that the element is at the point of yielding, therefore Tresca's Yield Criterion must
hold. If it is assumed that P and Q are the major and minor principal stresses for the element, then

 P-Q = σ0
 dP-dQ = dσ0
 dP = dQ [dσ =0, Where σ is the yield
0 0

stress of the metal]

 hdP = ±2Kdx
So, equation (iii) can be rewritten and integrated as,

=
dP ± dx

2K h
=±∫
dP dx
∫
2K h
=± +c ………………(iv)
P x

At the edges x=± a ,
2K h

So, according to Von Mises yield criterion, Sticking friction,  P+Q = 2K = σ0

again, at the edges, Q = 0, so the relation become,
 P = 2K
 2k ¿ ) = 2K [from (iv)]
x
h
 c = 1−
±a
h
 c = 1±
a
h
± = 1− [again, from (iv)]
P x ±a

2K h h
= ± + 1−
P x ±a

2K h h
=1+( − ¿
P x a

2K h h
 =1+ [ x=± a ]
P (a−x )

2K h
 P =2K (1+
a−x
¿
h

i.e., x = 0 is thus
This defines the friction hill for sticking friction. The maximum value of P at the center,

Pmax ¿ 2 K [1+ ]
a
h

Pmin = σ0 = 2K
When, x=± a

Pmean = (Pmin+ Pmax)/2

And the mean pressure becomes,

 P = 2 K [1+
a
]
2h

This is the final equation of friction hill due to the sticking friction.