ME 3221 - Spring 2012 Name:

Forging & Rolling Examples April 20, 2012

Example Forging Problem

A low-carbon annealed steel bar having an initial diameter of 125 mm is reduced in height
from 25 mm to 20 mm by open die forging. Estimate the maximum die force and work
required. Neglect friction for this estimate.
Solution:
From K&S Table 2.3:
K = 530 MPa
n = .26
True strain:
25
1 = ln = .2231
20
Initial area:
π
A0 = (d0 )2 = 12, 272 mm2
4
Flow stress at completion of forging:
N N
σyf = Kn1 = 530 (.2231).26
= 358.8
mm2 mm2
Maximum die force:
  
N 25  
Fmax = 358.8 12, 272 mm2 = 5.50 MN
mm2 20

Fmax = 5.50 MN

Part volume:
V = A0 h0 = .3068X10−3 m3
Total work required:
N (.3068X10−3 m3 )
KV n+1 530X106 m
(.2231)1.26 = 19.5 kN-m
2
Work = 1 =
n+1 1.26

Work = 19.5 kN-m

1
Sample Calculation for Predicting Roll Separating Force
Note: The calculations shown below are based on the following data, starting from a 4.70
mm (.185 inch) thick 6061-T0 aluminum plate (your calculations should use your data from
the Rolling Lab):
Previous Pass:

ti = 2.41 mm; L = 582 mm; w = 99 mm; Fact = 121 kN; σyf = 195 MPa

Current Pass:

to = 2.03 mm; L = 680 mm; w = 99 mm; Fact = 134 kN

Calculations:
Δt = to − ti = 0.38 mm
 
√ 133
LR = RΔt = mm (.38 mm) = 5.03 mm
2
 
tinit 4.70 mm
1,total = ln = ln = 0.840
to 2.03 mm
2
e = √ 1,total = .969
3
K = 205 MPa; n = 0.20 (K&S Table 2.3)
σyf = Kne = (205 MPa)(.969)0.20 = 204 MPa
1
Y ≈ (195 MPa + 204 MPa) = 200 MPa
2
2
σ 3 = − √ Y = −231 MPa
3
|F | = LR w |σ3 | = (5.03X10−3 m)(99X10−3 m)(231X106 Pa) = 115 kN
134 kN − 115 kN
= 14%
134 kN
Therefore, the predicted roll separating force is within 14% of the actual value for this pass.
This is a reasonable result, considering all of our modeling assumptions.
For all data points that I analyzed for this example, the results were best in the middle and
“so-so” at the ends. However, the order of magnitude of the forces was correct even at the
extremes.