Metal Forming

Dr. Arindam Kumar Chanda

Elastic and plastic deformation
Elastic and Plastic deformation
Elastic deformation is a
change in shape of a
material at low stress that
is recoverable after the
stress is removed.
This type of deformation
involves stretching of the
bonds, but the atoms do
not slip past each other.
When the stress is
sufficient to permanently
deform the metal, it is
called plastic deformation

Plastic deformation
involves the breaking of a
limited number of atomic
bonds in the crystal by
the movement of
dislocations
Hot Working Cold Working
Done at temperature above
recrystallization temperature
but below melting point.
Work hardening is eliminated.
Improvement of mechanical
properties like elongation,
reduction of area and impact
value
Refinement of crystal occurs

Cracks and blow holes are
welded up.
Promotes uniformity of
material
Internal and residual stresses
are not developed in metal
Done at temperature below
re-crystallization temperature
Work hardening is not
eliminated.
Decrease of mechanical
properties like elongation,
reduction of area and impact
value
Crystallization does not occur.
Grains are elongated and
distorted.
Possibility of crack formation
and propagation
Uniformity of material is lost
Internal and residual stresses
are developed in the metal.
Rolling
Bars, plates, sheets, rails and other
structural sections are made through
plain and grooved rolls.
Rolling Mill
Extrusion
Wire Drawing
Forging
Forging Press
Deep drawing
Deep drawing is defined as the process of making of cup shaped parts from flat metal
sheet. This process is also called cupping.
Piercing or Seamless tubing
Here a hot rolled billet is passed between two conical shaped rolls and over a mandrel
which assist in the piercing and control the size of the hole as the billet is forced over it.
Trescas Yield Criteria
Since the plastic flow depends on slip which
essentially is a shearing process, Tresca suggested
that The plastic flow initiates when the maximum
shear stress reaches a limiting value. This limiting
value is defined as shear yield stress K.
If the principal stresses at a point in the material are

1
,
2
, and
3
, then the maximum shear stress
max ,

is given by

max
= (
1
-
3
) / 2
Hence Trescas criteria becomes
(
1
-
3
) / 2 = K
Von Mises Yield Criteria
Von Mises proposed that the plastic flow occurs
when the shear strain energy per unit volume
reaches a critical value(say A). The shear strain
energy per unit volume is given by
1/6G[(
1
-
2
)
2
+ (
2

3
)
2
+ (
3

1
)
2
] , where G
is the shear modulus of the material. Hence
according to this criteria
1/6G[(
1
-
2
)
2
+ (
2

3
)
2
+ (
3

1
)
2
] = A
or, (
1
-
2
)
2
+ (
2

3
)
2
+ (
3

1
)
2
= 6GA
i.e. (
1
-
2
)
2
+ (
2

3
)
2
+ (
3

1
)
2
= C(Constant)