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 (µ) 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

unit depth
into figure
y
h
x
dx

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
Expanding the dx slice on LHS
p
τf • p = die pressure
• σx, dσx from material on
side
σx σx + dσx
• τfriction = friction force = µp

τf
p
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Force balance in x-direction
hdσ x + 2τ friction dx = 0
2τ friction
dσ x = − dx
h
k
Mohr’s circle

2 p σx
σ x + p = 2k = σ flow = 1.15 ⋅ σ flow
3
(distortion energy (von Mises) criterion, N.B. all done on a per
plane strain) unit depth basis

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Force balance
Differentiating, and substituting into Mohr’s
circle equation

d (2k ) = d (σ x + p ) ∴ dp = − dσ x
2τ friction  2τ friction 
dσ x = − dx ∴ dp =  dx
h  h 
noting: τfriction = µp
2µ dp 2 µ
dp = pdx = dx
h p h
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Sliding region

px
2µ
x
dp
∫2k p = ∫0 h dx

• Noting: @ x = 0, σx = 2k = 1.15 σflow

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging pressure – sliding
region
x
ln px − ln (2k ) = 2 µ
h
Sliding region result (0 < x < xk)
px  2 µx 
= exp 
2k  h 
 2 µx 
p x = 1.15 ⋅ σ flow ⋅ exp  N.B done on a
 h  per unit depth basis

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging pressure –
approximation
• Taking the first two terms of a Taylor’s
series expansion for the exponential
about 0, for x ≤ 1
0 0
2 3 n n
xk
∑
x x x
exp(x ) = 1 + x + + +L+ =
2! 3! n! k!
k =0
yields

p x  2 µx   2 µx 
= 1 +  p x = 1.15 ⋅ σ flow ⋅ 1 + 
2k  h   h 
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Average forging pressure –
all sliding approximation
• using the Taylor’s series approximation
w w w
2
px  2 µx 
2  2 µx 2
 2

∫
pave 0 2k
dx ∫ 1 +
0
dx  x +
h   2h  0

= = =
2k w w w
2 2 2
pave  µw 
= 1 + 
2k  2h 
 µw  N.B done on a
pave = 1.15 ⋅ σ flow ⋅ 1 +  per unit depth basis
 2h 
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Forging force –
all sliding approximation
F forging = pave ⋅ width ⋅ depth

 µw 
F forging = 1.15 ⋅ σ flow ⋅  1 +  ⋅ w ⋅ depth
 2h 

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Slab - die interface
• Sliding if τf < τflow
• Sticking if τf ≥ τflow
– can’t have a force on a material
greater than its flow (yield) stress
– deformation occurs in a sub-layer just
within the material with stress τflow

sliding
region
sticking
region
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Sliding / sticking transition
• Transition will occur at xk
• using k = µp, in:
px  2 µx  k  2 µxk 
= exp  = exp 
2k  h  2 µk  h 
• hence:
xk 1 1
= ln
h 2µ 2µ
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Sticking region
2µ
dp = pdx
h
• Using p = k/ µ
2µ k
dp = dx
h µ
px x
2k 2k
∫p dp = x∫ h dx p x − p xk = ( x − xk )
kx k
h

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Sticking region
We know that
• at x = xk, px = k/µ
k

• and xk 1 1
= ln
h 2µ 2µ

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging pressure - sticking
region
Combining (for xk < x < w/2)

px 1   1  x
= 1 − ln  
  +
2k 2 µ   2 µ 
 h

 1   1  x 
p x = 1.15 ⋅ σ flow ⋅  1 − ln    + 
 2 µ   2 µ   h 

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging pressure –
all sticking approximation
• If xk << w, we can assume all sticking,
and approximate the total forging force
per unit depth (into the figure) by:

∆p
pedge

0
x=0 x=w/2
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Forging pressure –
all sticking approximation
pedge = 2k
px x
2k 2k
∫2k dp = ∫0 h dx p x − 2k = (x )
h
px  x
∴ = 1 + 
2k  h 
 x
p x = 1.15 ⋅ σ flow ⋅ 1 + 
 h
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Average forging pressure –
all sticking approximation
w w w
2
px  x2  x 
2 2

∫
pave 0 2k
dx ∫ 1 + dx
0
h
 x + 
 2h  0
= = =
2k w2 w2 w2
pave  w
= 1 + 
2k  4h 
 w
pave = 1.15 ⋅ σ flow ⋅ 1 + 
 4h 
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Forging force –
all sticking approximation

F forging = pave ⋅ width ⋅ depth

 w
F forging = 1.15 ⋅ σ flow ⋅ 1 +  ⋅ w ⋅ depth
 4h 

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Sticking and sliding
• If you have both sticking and sliding, and you
can’t approximate by one or the other,
• Then you need to include both in your
pressure and average pressure calculations.

Fforging = Fsliding + Fsticking

F forging = ( pave ⋅ A)sliding + ( pave ⋅ A)sticking

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Material Models
Strain hardening (cold – below recrystallization point)

σ flow = Y = Kε n

Strain rate effect (hot – above recrystallization point)

σ flow = Y = C (ε& ) m

1 dh v platen velocity
ε& = = =
h dt h instantaneous height

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging - Ex. 1-1
• Lead 1” x 1” x 36” 36”
• σy = 1,000 psi 1”

• hf = 0.25”, µ = 0.25 1”
• Show effect of friction on total forging force.
• Use the slab method.
• Assume it doesn’t get wider in 36” direction.
• Assume cold forging.

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging - Ex. 1-2
• At the end of forging:
hf = 0.25”, wf = 4” (conservation of mass)

• Sliding / sticking transition

xk 1 1
= ln
h 2µ 2µ
0.25 1
xk = ln = 0.347"
2 × 0.25 2 × 0.25
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Forging - Ex. 1-3
• Sliding region:

 2 µx 
px = 1.15 ⋅ σ flow ⋅ exp 
 h 
 f 
= 1150 ⋅ exp(2 x )

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging - Ex. 1-4
• Sticking region

 1   1  x 
p x = 1.15 ⋅ σ flow ⋅  1 − ln   + 
 2 µ   2µ   h f 
= 1150 ⋅ (0.6 + 4 x )

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging - Ex. 1-5
sliding
sliding sticking
friction
12000 hill
Forging pressure (psi)

10000
8000 xk
xk
6000
4000 P(sticking)
2000 P(sliding)
0
0 0.5 1 1.5 2 2.5 3 3.5 4
Distance from forging edge (in)

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:

Force = ∫∫ p ⋅dA

• since we have plane strain

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

  xk     w/ 2  
F forging = 2  ∫ p x dx .depth  + 2  ∫ p x dx .depth 
 0    x  
    sliding  k   sticking

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging - Ex. 1-9
Sliding first
xk
pave  2 µx 
1.15σ flow ∫0 exp h dx h  2µx  xk
= = exp 
unit depth xk − 0 2µ  h 0

h   2 µxk  
exp  − 1
2µ   h  
=
(xk − 0)
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Forging - Ex. 1-12
Substituting values
sliding
pave 0.25   2 × 0.25 × 0.347  
 exp  − 1
1.15σ flow 2 × 0.25   0.25  
= = 1.44
unit depth (0.347 − 0)
sticking
pave 1  1  4  1  42 2
1 − ln  − 0.347  +  − 0.347 
1.15σ flow 2 × 0.25  2 × 0.25  2  2 × 0.25  4 
=
unit depth 4
− 0.347
2
= 5.3
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Forging - Ex. 1-10
Sticking next
w
pave  1 
2
1  x
1.15σ flow
∫x  2µ 1 − ln 2µ  + h dx
= k
unit depth w −x
2 k
w
 1  2
1  x2 
 1 − ln  ⋅ x + 
 2µ  2µ  2h 
=
 w −x 
 2 k 
 
xk
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Forging - Ex. 1-11

pave
1.15σ flow
1 
1 − ln
2µ 
1 w
(
 2 − xk +
2µ 
1  w2

2h  4
)2
− xk 
= 
unit depth w −x
2 k

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging - Ex. 1-13

Now calculate the area/unit depth

Asliding = 0.347 × 2 = 0.69

Asticking = 4 − 2 × 0.347 = 3.31

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging - Ex. 1-14
Now calculate the forces

F
unit depth
(
= 1.15σ flow ( pave ⋅ A)sliding + ( pave ⋅ A)sticking )

F
= 1150 × ((1.44 × 0.69 ) + (5.3 × 3.31))
unit depth
= 21,110 lb / inch

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging - Ex. 1-15
• Now, assume all sticking, so:

F  wf 
= 1.15σ flow ⋅ w f ⋅ 1 + 
unit length  4h 
 f 
 4 
= 1150 ⋅ 4 ⋅ 1 + 
 4 ⋅ 0.25 
= 23,000 lb / inch depth

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

 w
F forging = 1.15 ⋅ σ flow ⋅ 1 +  ⋅ w ⋅ depth
 4h 
F(all sticking) = 828,000 lbs = 414 tons

 µw 
F forging = 1.15 ⋅ σ flow ⋅ 1 +  ⋅ w ⋅ depth
 2h 

F(all sliding) = 496,800 lbs = 225 tons

All sticking over-estimates actual value.

Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Forging – Effect of friction
• Effect of friction coefficient (µ) – all sticking
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
• Friction is very important
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
 Forging - Ex. 1-17
Forging force vs. stroke – all sticking
25000
Forging force (lbf/in

mu=0
20000 mu=0.1
mu=0.2
15000 mu=0.25
depth)

mu=0.3
10000 mu=0.4
mu=0.5
5000
0
0 0.2 0.4 0.6 0.8
Stroke (in)

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton
 Forging - Ex. 1-19
Maximum forging force vs. friction coefficient (µ)
all sticking
25000
20000
Max forging force
(lbf/in depth)

15000
10000
5000
0
0 0.1 0.2 0.3 0.4 0.5 0.6
Friction coefficient

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
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton