Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Fundamentals of
metalworking
Subjects of interest
• Introduction/objectives
• Classification of metal processes
• Mechanics of metalworking
• Flow curves
• Effects of temperature on metalworking
- Hot working
- Cold working
• Effects of metallurgical structure on forming processes
• Effects of speed of deformation on forming processes
• Effects of friction and lubricant
• Direct-compression-type processes
• Indirect-compression processes
• Tension type processes
• Bending processes
• Shearing processes
• Bending processes:
the applied force involves the
application of bending moments
to the sheet.
• Shearing processes:
the applied force involves the
application of shearing forces of
sufficient magnitude to rupture the
metal in the plane of shear.
Metal forming
h1 − ho h1
For conventional strain
e= = −1 …Eq. 3
ho ho
ho ho − h1 h1
ε c = ln , ec = = 1− …Eq. 4
h1 ho ho
And the fractional reduction Ao − A1
(reduction of area) in metal working r= …Eq. 5
Ao
deformation is given by
From the constant-volume relation A1 L1 = Ao Lo
A1 A1
Ao
Lo
r = 1− or = 1− r
Ao Ao
L1 Ao 1
σ A1 L1 σ ε = ln = ln = ln
Lo A1 1− r
…Eq. 6
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
Example: Determine the engineering strain, true strain, and
reduction for (a) a bar which is doubled in length and (b) a bar
which is halved in length.
• Once the metal has reached its yield point, the metal starts to
flow under the influence of stress state. This is in the plastic regime
where stress is not directly proportional to strain.
• The manner of flow or deformation is dependent on the stress
state.
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
FEM analysis
Flow curve
σy
True stress, σ
True stress
0 10 20 30 40 50
Reduction of area by drawing, % True strain, ε εf
Flow curve constructed from stress- Method of using average flow
strain curves after different amounts of stress to compensate for strain
reduction. hardening.
Ductility
Properties
Strength
Hardness
Aluminium sheet
Critical
deformation
5 10 15 20 25
Plastic deformation, %
Ductility
Properties
Strength
Grain size
Polygonization www.esrf.fr
Disdvantages
• Use high amount of deformation due to low operating temperatures,
therefore, require soft materials.
• Equipment (rolls, dies, presses) is big and expensive.
• Reduced ductility, therefore, require subsequent annealing treatments.
Mechanical
Hot rolled Cold rolled
properties
Ultimate tensile
strength, σTS 427 558
(MPa)
Yield stress, σy
220 345
(MPa)
Brinell hardness
94 174
(HB)
microcrack
F τ i Ar τ i
µ= = =
P pAr p …Eq.15
Where
µ = frictional coefficient
τ = the shearing stress at the interface
P = the load normal to the interface
F = the shearing force
(a) Contact at asperities (b) overlap of Ar= summation of asperity areas in contact
deformation zones to produce subsurface
shear zone. p = the stress normal to the interface
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
Example : homogeneous compression of a flat circular disk
σ
τ
µ=
p
σ
Where
µ = frictional coefficient
τ = the shearing stress at the interface
p = the stress normal to the interface
h
σo
-a a X