FUNDAMENTALS OF METAL FORMING

Rolling
Forging
Extrusion
Deep drawing
Wire drawing
FUNDAMENTALS OF METAL
FORMING
Overview of Metal Forming
Material Behavior in Metal Forming
Temperature in Metal Forming
Strain Rate Sensitivity
Friction and Lubrication in Metal Forming
Metal Forming
Large group of manufacturing processes in which plastic
deformation is used to change the shape of metal work
pieces
The tool, usually called a die, applies stresses that
exceed yield strength of metal
The metal takes a shape determined by the geometry of
the die
Bulk Deformation Processes
Characterized by significant deformations
and massive shape changes
"Bulk" refers to work parts with relatively
low surface area to volume ratios
Starting work shapes include cylindrical
billets and rectangular bars
Direct-compression-
type process
Indirect-
compression process
Tension-type process
Bending process
Shearing process
Metal Working Classification
Basis: type of force applied to the work piece
Basic bulk deformation processes:
Rolling
Basic bulk deformation processes:
Forging
Basic bulk deformation processes:
Extrusion
Basic bulk deformation processes:
Drawing
Sheet Metalworking
Forming and related operations performed on metal
sheets, strips, and coils
High surface area to volume ratio of starting metal,
which distinguishes these from bulk deformation
Often called press-working because presses perform
these operations
- Parts are called stampings
- Usual tooling: punch and die
Basic sheet metalworking operation:
Bending
Basic sheet metalworking operation:
Deep Drawing
Basic sheet metalworking operation:
Shearing
Stresses in Metal Forming
Stresses to plastically deform the metal
are usually compressive
- Examples: rolling, forging, extrusion
However, some forming processes
- Stretch the metal (tensile stresses)
- Others bend the metal (tensile and
compressive)
- Still others apply shear stresses
Material Properties in Metal Forming
Desirable material properties:
- Low yield strength and high ductility
These properties are affected by
temperature:
- Ductility increases and yield strength
decreases when work temperature is
raised
Other factors:
- Strain rate and friction
Material Behavior in Metal Forming
Plastic region of stress-strain curve is primary
interest because material is plastically deformed
In plastic region, metal's behavior is expressed by
the flow curve:
where K = strength coefficient; and n = strain
hardening exponent
Stress and strain in flow curve are true stress and
true strain
n
t
K =
Typical values of K and n (
t
= K
n
)
MATERIAL K (MPa) n
Aluminum, 1100-O
2024-T4
5052-O
6061-O
6061-T6
7075-O
Brass, 70-30, annealed
85-15, cold-rolled
Bronze (phosphor), annealed
Cobalt-base alloy, heat treated
Copper, annealed
Molybdenum, annealed
Steel, low-carbon, annealed
1045 hot-rolled
1112 annealed
1112 cold-rolled
4135 annealed
4135 cold-rolled
4340 annealed
17-4 P-H annealed
52100 annealed
304 stainless, annealed
410 stainless, annealed
180
690
210
205
410
400
895
580
720
2070
315
725
530
965
760
760
1015
1100
640
1200
1450
1275
960
0.20
0.16
0.13
0.20
0.05
0.17
0.49
0.34
0.46
0.50
0.54
0.13
0.26
0.14
0.19
0.08
0.17
0.14
0.15
0.05
0.07
0.45
0.10
Engineering stress strain curve
True Stress (
t
) & Strain ()
Flow curve
Flow Stress
For most metals at room temperature, strength increases
when deformed due to strain hardening
Flow stress = instantaneous value of stress required to
continue deforming the material
where Y
f
= flow stress (true stress), that is, the yield
strength as a function of strain
n
f
K Y =
Average Flow Stress
Determined by integrating the flow curve equation between zero
and the final strain value defining the range of interest
Where = maximum strain during deformation process
n
K
Y
n
f
+
=
1
_

True strain
Temperature in Metal Forming
For any metal, K and n in the flow curve depend on
temperature
Both strength and strain hardening are reduced at
higher temperatures
In addition, ductility is increased at higher
temperatures
Temperature in Metal Forming
Any deformation operation can be accomplished with
lower forces and power at elevated temperature
Three temperature ranges in metal forming:
- Cold working
- Warm working
- Hot working
Influence of Annealing Temperature on the
Tensile Strength and Ductility of a Brass Alloy
Influence of Annealing Temperature on the
Tensile Strength and Ductility of a Brass Alloy
Hot Working
Deformation at temperatures above recrystallization
temperature
Recrystallization temperature = about one-half of
melting point on absolute scale
1. In practice, hot working usually performed
somewhat above 0.5T
m
2. Metal continues to soften as temperature
increases above 0.5T
m
, enhancing advantage of
hot working above this level