Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

Forging Analysis - 1
ver. 1
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Overview
Slab analysis
frictionless
with friction
Rectangular
Cylindrical
Strain hardening and rate effects
Flash
Redundant work
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Slab analysis assumptions
Entire forging is plastic
no elasticity
Material is perfectly plastic
strain hardening and strain rate effects
later
Friction coefficient () is constant
all sliding, to start
Plane strain
no z-direction deformation
In any thin slab, stresses are uniform
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Open die forging analysis
rectangular part
F
F
h
w
dx
y
x
unit depth
into figure
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Expanding the dx slice on LHS
p = die pressure

x
, d
x
from material on
side

friction
= friction force = p
p
p

x

x
+ d
x

f
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Force balance in x-direction
p
x
k
dx
h
d
dx hd
friction
x
friction x

2
0 2
=
= +
Mohrs circle
(distortion energy (von Mises) criterion,
plane strain)
flow flow x
k p = = = + 15 . 1
3
2
2
N.B. all done on a per
unit depth basis
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Force balance
Differentiating, and substituting into Mohrs
circle equation
noting:
friction
= p
pdx
h
dp
2
= dx
h p
dp 2
=
( ) ( )
dx
h
dp dx
h
d
d dp p d k d
friction friction
x
x x
|
|
.
|

\
|
= =
= + =

2 2
2
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Sliding region
Noting: @ x = 0,
x
= 2k = 1.15
flow
dx
h p
dp
x
p
k
x

=
0 2
2
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging pressure sliding
region
( )
|
.
|

\
|
=
|
.
|

\
|
=
=
h
x
p
h
x
k
p
h
x
k p
flow x
x
x

2
exp 15 . 1
2
exp
2
2 2 ln ln
Sliding region result (0 < x < x
k
)
N.B done on a
per unit depth basis
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging pressure
approximation
Taking the first two terms of a Taylors
series expansion for the exponential
about 0, for
|
.
|

\
|
+ =
h
x
k
p
x
2
1
2
1 x
yields
( )

=
= + + + + + =
n
k
k n
k
x
n
x x x
x x
0
3 2
! ! ! 3 ! 2
1 exp L
0 0
|
.
|

\
|
+ =
h
x
p
flow x

2
1 15 . 1
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Average forging pressure
all sliding approximation
using the Taylors series approximation
2
2
2
2
2
1
2
2
2
2
0
2
2
0
2
0
w
h
x
x
w
dx
h
x
w
dx
k
p
k
p
w
w w
x
ave
|
|
.
|

\
|
+
=
|
.
|

\
|
+
= =

N.B done on a
per unit depth basis
|
.
|

\
|
+ =
h
w
k
p
ave
2
1
2

|
.
|

\
|
+ =
h
w
p
flow ave
2
1 15 . 1

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
Forging force
all sliding approximation
depth w
h
w
F
flow forging

|
.
|

\
|
+ =
2
1 15 . 1

depth width p F
ave forging
=
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Slab - die interface
Sliding if
f
<
flow
Sticking if
f

flow
cant have a force on a material
greater than its flow (yield) stress
deformation occurs in a sub-layer just
within the material with stress
flow
sliding
region
sticking
region
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Sliding / sticking transition
Transition will occur at x
k
using k = p, in:
hence:
2
1
ln
2
1
=
h
x
k
|
.
|

\
|
=
h
x
k
p
x
2
exp
2
|
.
|

\
|
=
h
x
k
k
k

2
exp
2
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Sticking region
Using p = k/
pdx
h
dp
2
=
( )
k x x
x x
h
k
p p
k
=
2
dx
h
k
dp
x
x
p
p
k
x
k
x

=
2
dx
k
h
dp

2
=
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Sticking region
We know that
at x = x
k
, p
x
k
= k/
and
2
1
ln
2
1
=
h
x
k
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging pressure - sticking
region
h
x
k
p
x
+
|
|
.
|

\
|
|
|
.
|

\
|
=
2
1
ln 1
2
1
2
Combining (for x
k
< x < w/2)
(
(

+
|
|
.
|

\
|
|
|
.
|

\
|
=
h
x
p
flow x

2
1
ln 1
2
1
15 . 1
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging pressure
all sticking approximation
If x
k
<< w, we can assume all sticking,
and approximate the total forging force
per unit depth (into the figure) by:
x=0 x=w/2
0
p
edge
p
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging pressure
all sticking approximation
k p
edge
2 =
|
.
|

\
|
+ =
|
.
|

\
|
+ =
h
x
p
h
x
k
p
flow x
x
1 15 . 1
1
2

( ) x
h
k
k p
x
2
2 =
dx
h
k
dp
x
p
k
x

=
0 2
2
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Average forging pressure
all sticking approximation
2
2
2
1
2
2
2
2
0
2
2
0
2
0
w
h
x
x
w
dx
h
x
w
dx
k
p
k
p
w
w w
x
ave
|
|
.
|

\
|
+
=
|
.
|

\
|
+
= =

|
.
|

\
|
+ =
h
w
k
p
ave
4
1
2
|
.
|

\
|
+ =
h
w
p
flow ave
4
1 15 . 1
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging force
all sticking approximation
depth w
h
w
F
flow forging

|
.
|

\
|
+ =
4
1 15 . 1
depth width p F
ave forging
=
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Sticking and sliding
If you have both sticking and sliding, and you
cant approximate by one or the other,
Then you need to include both in your
pressure and average pressure calculations.
( ) ( )
sticking
ave
sliding
ave forging
A p A p F + =
sticking sliding forging
F F F + =
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Material Models
n
flow
K Y = =
Strain hardening (cold below recrystallization point)
Strain rate effect (hot above recrystallization point)
( )
m
flow
C Y
&
= =
height ous instantane
velocity platen
h
v
dt
dh
h
1
= = =
&
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-1
Lead 1 x 1 x 36

y
= 1,000 psi
h
f
= 0.25, = 0.25
Show effect of friction on total forging force.
Use the slab method.
Assume it doesnt get wider in 36 direction.
Assume cold forging.
1
1
36
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-2
At the end of forging:
h
f
= 0.25, w
f
= 4 (conservation of mass)
Sliding / sticking transition
" 347 . 0
25 . 0 2
1
ln
25 . 0 2
25 . 0
2
1
ln
2
1
=

=
=
k
k
x
h
x

Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-3
Sliding region:
( ) x
h
x
p
f
flow x
2 exp 1150
2
exp 15 . 1
=
|
|
.
|

\
|
=

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
Forging - Ex. 1-4
Sticking region
( ) x
h
x
p
f
flow x
4 6 . 0 1150
2
1
ln 1
2
1
15 . 1
+ =

)

+
|
|
.
|

\
|
|
|
.
|

\
|
=

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
Forging - Ex. 1-5
0
2000
4000
6000
8000
10000
12000
0 0.5 1 1.5 2 2.5 3 3.5 4
Distance from forging edge (in)
F
o
r
g
i
n
g

p
r
e
s
s
u
r
e

(
p
s
i
)
P(sticking)
P(sliding)
sticking sliding
sliding
friction
hill
x
k
x
k
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-6
Friction hill
forging pressure must be large (8.7x) near the
center of the forging to push the outer
material away against friction
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-7
Determine the forging force from:
since we have plane strain
dA p Force

=
dx p
depth unit
F
x
x

=
0
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-8
We must solve separately for the sliding
and sticking regions
sticking
w
x
x
sliding
x
x forging
depth dx p depth dx p F
k
k
|
|
.
|

\
|
|
|
.
|

\
|
+
|
|
.
|

\
|
|
|
.
|

\
|
=

. 2 . 2
2 /
0
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-9
Sliding first
k
k
x
k
x
flow
ave
h
x h
x
dx
h
x
depth unit
p
0
0
2
exp
2 0
2
exp
15 . 1
|
.
|

\
|
=

|
.
|

\
|
=

( ) 0
1
2
exp
2

|
.
|

\
|
=
k
k
x
h
x h

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
Forging - Ex. 1-12
Substituting values
( )
44 . 1
0 347 . 0
1
25 . 0
347 . 0 25 . 0 2
exp
25 . 0 2
25 . 0
15 . 1
=

|
.
|

\
|

=
depth unit
p
flow
ave

3 . 5
347 . 0
2
4
347 . 0
4
4
25 . 0 2
1
347 . 0
2
4
25 . 0 2
1
ln 1
25 . 0 2
1
15 . 1
2
2
=

|
|
.
|

\
|

+
|
.
|

\
|

|
.
|

\
|

=
depth unit
p
flow
ave

sliding
sticking
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-10
Sticking next
k
w
x flow
ave
x
w
dx
h
x
depth unit
p
k

|
|
.
|

\
|
+ |
.
|

\
|

=

2
2
1
ln 1
2
1
15 . 1
2

2
2
2
2 2
1
ln 1
2
1
w
x
k
k
x
w
h
x
x
(
(
(
(
(

+
|
|
.
|

\
|

=

Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-11
( )
k
k k
flow
ave
x
w
x
w
h
x
w
depth unit
p

|
|
.
|

\
|
+ |
.
|

\
|

=
2
4 2
1
2
2
1
ln 1
2
1
15 . 1
2
2

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
Forging - Ex. 1-13
Now calculate the area/unit depth
31 . 3 347 . 0 2 4
69 . 0 2 347 . 0
= =
= =
sticking
sliding
A
A
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-14
Now calculate the forces
( ) ( ) ( )
sticking
ave
sliding
ave flow
A p A p
depth unit
F
+ = 15 . 1
( ) ( ) ( )
inch lb
depth unit
F
/ 110 , 21
31 . 3 3 . 5 69 . 0 44 . 1 1150
=
+ =
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-15
Now, assume all sticking, so:
depth inch lb
h
w
w
length unit
F
f
f
f flow
/ 000 , 23
25 . 0 4
4
1 4 1150
4
1 15 . 1
=
|
.
|

\
|

+ =
|
|
.
|

\
|
+ =
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-16
or since the part is 36 deep:
F(both) = 759,960 lbs = 380 tons
F(all sticking) = 828,000 lbs = 414 tons
F(all sliding) = 496,800 lbs = 225 tons
All sticking over-estimates actual value.
depth w
h
w
F
flow forging

|
.
|

\
|
+ =
4
1 15 . 1
depth w
h
w
F
flow forging

|
.
|

\
|
+ =
2
1 15 . 1

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
Forging Effect of friction
Effect of friction coefficient () all sticking
Friction is very important
Friction coefficient Fmax (lbf/in depth) xk Stick/slide
0 4600 2 slide
0.1 11365 2 slide
0.2 19735 0.573 both
0.25 21331 0.347 both
0.3 22182 0.213 both
0.4 22868 0.070 both
0.5 23000 0 stick
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-17
Forging force vs. stroke all sticking
0
5000
10000
15000
20000
25000
0 0.2 0.4 0.6 0.8
Stroke (in)
F
o
r
g
i
n
g

f
o
r
c
e

(
l
b
f
/
i
n
d
e
p
t
h
)
mu=0
mu=0.1
mu=0.2
mu=0.25
mu=0.3
mu=0.4
mu=0.5
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-19
Maximum forging force vs. friction coefficient ()
all sticking
0
5000
10000
15000
20000
25000
0 0.1 0.2 0.3 0.4 0.5 0.6
Friction coefficient
M
a
x

f
o
r
g
i
n
g

f
o
r
c
e

(
l
b
f
/
i
n

d
e
p
t
h
)
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Summary
Slab analysis
frictionless
with friction
Rectangular
Cylindrical
Strain hardening and rate effects
Flash
Redundant work