Deformation system

Primary Manufacturing process

Source: Courtesy: E. Paul DeGarmo, P.E, Macmillan Publ.co.,Inc.N.Y, Collier Macmillan Publ. London, Davic Associates,Inc 1974

Deformation System

1. Plastic Zone, 2. Initial Surface Aspects of Work Piece, 3. Properties of Entry Metal 4. Tribology Zone, 5. Tool Zone, 6. Properties of the Exit Metal, 7. Machine Zone, 8. Auxiliary Zone

Plastic zone
Plastic Zone Flow Stress Deformation Ratio, d = - dh/h Deformation Rate, = - (d)/(dt) = - (dh/h)/(dt) = V/h, sec-1 Machine Characteristics Deformation Temperature, act = Other Material Properties, Hall petch equation, Isotropic condition etc Formability of materials, defects, state of stress

Stages for formability

Stages,Properties, Energy

Initial Workpiece condition

Initial Work Piece Condition Chemical Composition
Force and Energy State of Temp.

Crystal Structure like FCC, BCC, HCP etc

Grain Size Hall Petch Eqn.-Force

1. Flow stress, F 2. Force and Energy considerations 3. Proper selection of temperature to cause plastic deformation depending upon the structure & chemical composition 4. Vide 3, decision to choose type of stresses and rate 5. F (fluctuation in force affecting tolerance on forming)

Work Piece Surface Condition

Reaction with Atmosphere, Reaction with Lubricant Absorption of detrimental gases Leading to damaging mechanism

Leads to: Plasticity getting defeated End Properties Undesirable

Tribology

Tribological Sector in The deformation Zone

FRICTION

WEAR

LUBRICATION

Relative Velocity

Heat & Pressure

Function of Pressure, Heat & Film Strength

Reduce stresses, Facilitate flow, Increase tool life, ensure quality products, reduce production stages etc.

Tool Galling

Tool Pickup

Dip the thumb in boiled water

The boil is formed. (Tool pickup)

Peeled boil exposes the virgin skin (Tool galling)

A simple analogy for tool pickup and galling

Septic thumb

Tool Zone
Tooling should aim to facilitate flow of material. reduce friction, wear and tool galling. Tool design should envisage production sequence to ensure controlled delegation of load and material flow. Tool design should envisage cost constraints as well constraints arising out of existing machine drive limitations. Amortization cost should be aimed favorably by metallurgical considerations in terms of evolving methodologies of reducing the forming stress. Tool stiffness should be aimed high. Low stiffness pulls down the total stiffness of the system resulting in less accurate product and decreasing the forming efficiency.

C.I.R.P. 5124

Importance of tool stiffness

Lower stiffness decreases the productivity.

c = ne m
C = stiffness m = mass, then, C/ m = natural frequency, ne decreases. Thus operating frequency has to be reduced to avoid resonance and tool failure.

Hydraulic press

Hydraulic press with extrusion die set up

Characterization Total Stiffness of Metal Forming System

IMPORTANCE OF TOOL ZONE

QUOTE: From KURT LANGE Success of Metal Forming Depends on Tooling.

Spn.

Before

After

F Upsetting

Useful Work, WD

Area under triangle = (1/2) (F) (e)., C = F/e., Area becomes (1/2) (F)(F/C) = F2 /2C = LK Which is same as spring work

LK = F2 /2C
Stroke, mm
e = elastic deformation

Typical Force Stroke Diagram to enumerate the importance of Stiffness of Tools

IMPORTANCE OF TOOL ZONE

Spring Loss = LK = F2 / 2C and this increases with lower stiffness. Vide above, the useful deformation work, Wd decreases., the deformation efficiency decreases.

Clutch & Flywheel

Formed Part

Mechanical Press

Schematic of the Spring System

Some methods to reduce cutting forces

Courtesy: Hand Book of Metal Forming, Schuler

Courtesy: Hand Book of Metal Forming, Schuler

Initial Work Piece Characteristics

Forming Forces

Stiffness of tools, machine

Initial Work Piece Characteristics

F = f (, , ) ,
END PIECE CHARACTERISTICS Dimensional Error Positional/Form Error Surface Error Material Properties Error

Deviation from Nominal Dimn. Eg:base dimn

Position error spring back, mismtch

Worms/Scores/ Scales, orange peel defect Surface error

Earing, res.stress,notc h effect matl. error

References
Source: Courtesy : Hand Book of Metal Forming, Kurt Lange, McGraw Hill Publ.,NY, 1985 ICFG Data Sheets, ASM Publ. 1970/75 Compendium of press tools for metal forming, P.Venugopal, IIT Madras