MF7203 THEORY OF METAL FORMING

L T P C3 0 0 3

AIM: To impart knowledge on plasticity, surface treatment for forming of various types of metal forming process. OBJECTIVES: To study the basic concepts of metal forming techniques and to develop force calculation in metal forming process. To study the thermo mechanical regimes and its requirements of metal forming

UNIT I THEORY OF PLASTICITY

Theory of plastic deformation Yield criteria Tresca and Von mises !istortion energy "tress strain relation #ohr$s circle representation of a state of stress cylindrical and spherical co ordinate system upper and lower bound solution methods %verview of &'# applications in #etal &orming analysis. UNIT II THEORY AND PRACTICE OF BULK FORMING PROCESSES 8 (nalysis of plastic deformation in &orging, )olling, '*trusion, rod+wire drawing and tube drawing 'ffect of friction calculation of forces, work done ,rocess parameters, equipment used !efects applications )ecent advances in &orging, )olling, '*trusion and !rawing processes !esign consideration in forming. UNIT III SHEET METAL FORMING 8 &ormability studies -onventional processes . ' ) & techniques "uperplastic forming techniques .ydro forming "tretch forming /ater hammer forming ,rinciples and process parameters (dvantage, 0imitations and application. UNIT IV POWDER METALLURGY AND SPECIAL FORMING PROCESSES Tooling, process parameters and applications. 9 %verview of ,+# technique (dvantages applications ,owder preform forging powder rolling %rbital forging 1sothermal forging .ot and cold 9 isostatic pressing .igh speed e*trusion )ubber pad forming &ine blanking 0("') beam forming UNIT V SURFACE TREATMENT AND METAL FORMING APPLICATIONS '*periment techniques of evaluation of friction in metal forming selection influence of temperature and gliding velocity &riction heat generation &riction between metallic layers 0ubrication carrier layer "urface treatment for drawing, sheet metal forming, '*trusion, hot and cold forging. ,rocessing of thin (l tapes -ladding of (l alloys !uple* and triple* steel rolling Thermo mechanical regimes of Ti and (l alloys during deformation &ormability of welded blank sheet 0aser structured steel sheet &ormability of laminated sheet. T%T(0: 23 ,')1%!"
REFERENCES: 4. .elmi ( Youssef, .assan (. 'l .ofy, #anufacturing Technology: #aterials, ,rocesses and 'quipment, -)publication press, 5645. 5. "(' Transactions, 7ournal of #aterials and #anufacturing "ection 3, 4889 566: 9. "urender kumar, Technology of #etal &orming ,rocesses, ,rentice .all 1ndia ,ublishers,5646 2. #arciniak,;., !uncan 7.0., .u ".7., <#echanics of "heet #etal &orming$, =utterworth .einemann (n 1mprint of 'lesevier, 566> 3. ?agpal @.)., #etal &orming ,rocesses Ahanna publishers, 5663. >. (ltan T., #etal forming &undamentals and applications (merican "ociety of #etals, #etals park, 5669 :. ("# .and book, &orming and &orging, ?inth edition, Vol 42, 5669 B. ".1)% A%=(Y(".1, "%% 1A oh (0T(?, T,#etal forming and &inite 'lement #ethod, %*ford Cniversity ,ress, 5664. 8. ,roc. %f ?ational "eminar on D(dvances in #etal &ormingE #1T, #arch 5666 46. !ieter @.'., #echanical #etallurgy F)evised 'dition 11G #c@raw .ill -o., 48BB 44. (0T(?.T, "%% 1A oh, @'@'0, .0 #etal forming, fundamentals and (pplications, (merican "ociety of #etals, #etals ,ark, %hio, 4883.

Lecture 1 FUNDAMENTALS OF METAL FORMING There are four basic production processes for producing desired shape of a product. These are casting, machining, joining (welding, mechanical fastners, epoxy, etc.), and deformation processes. Casting process exploit the fluidity of a metal in liquid state as it takes shape and solidifies in a mold. achining processes pro!ide desired shape with good accuracy and precision but tend to waste material in the generation of remo!ed portions. "oining processes permit complex shapes to be constructed from simpler components and ha!e a wide domain of applications. #eformation processes exploit a remarkable property of metals, which is their ability to flow plastically in the solid state without deterioration of their properties. $ith the application of suitable pressures, the material is mo!ed to obtain the desired shape with almost no wastage. The required pressures are generally high and the tools and equipment needed are quite expensi!e. %arge production quantities are often necessary to justify the process.

Fig 1.1 &tate of the stresses metal undergo during deformation. 's a metal is deformed (or formed, as often called) into useful shape, it experiences stresses such as tension, compression, shear, or !arious combinations there of (ig ).) illustrates these states of stresses. &ome common metal forming

processes are schematically gi!en in (ig ).* along with the state of stress(es) experienced by the metal during the process. Numb Process er +olling State of Stress i Mai Part Duri g Formi g

,i-axial compression

(orging

Tri-axial compression

/xtrusion

Tri-axial compression

swaging

,i-axial compression

#eep

2n flange of blank, biaxial tension and compression. 2n wall of cup, simple uni-axial tension.

drawing $ire and tube drawing ,i-axial compression, tension.

&traight bending

't bend, bi-axial compression and bi-axial tension

Fig 1.! Common metal forming processes. &tate of stress experienced by metal is

also gi!en To understand the forming of metal, it is important to know the structure of metals. etals are crystalline in nature and consist of irregularly shaped grains of !arious si5es. /ach grain is made up of atoms in an orderly arrangement, known as a lattice. The orientation of the atoms in a grain is uniform but differs in adjacent grains. $hen a force is applied to deform it or change its shape, a lot of changes occur in the grain structure. These include grain fragmentation, mo!ement of atoms, and lattice distortion. &lip planes de!elop through the lattice structure at points where the atom bonds of attraction are the weakest and whole blocks of atoms are displaced. The orientation of atoms, howe!er, does not change when slip occurs. To deform the metal permanently, the stress must exceed the elastic limit. 't room temperature, the metal is in a more rigid state than when at higher temperature. Thus, to deform the metal greater pressures are needed when it is in cold state than when in hot state. $hen metal is formed in cold state, there is no recrystalli5ation of grains and thus reco!ery from grain distortion or fragmentation does not take place. 's grain deformation proceeds, greater resistance to this action results in increased hardness and strength. The metal is said to be strain hardened. There are se!eral theories to explain this occurrence. 2n general, these refer to resistance build up in the grains by atomic dislocation, fragmentation, or lattice distortion, or a combination of the three phenomena. The amount of deformation that a metal can undergo at room temperature depends on its ductility. The higher the ductility of a metal, the more the deformation it can undergo. 6ure metals can withstand greater amount of deformation than metals ha!ing alloying elements, since alloying increases the tendency and rapidity of strain hardening. etals ha!ing large grains are more ductile than those ha!ing smaller grains. $hen metal is deformed in cold state, se!ere stresses known as residual stresses are set up in the material. These stresses are often undesirable, and to remo!e them the metal is heated to some temperature below the recrystalline range temperature. 2n this temperature range, the stresses are rendered ineffecti!e without appreciable change in physical properties or grain structure. "OLD AND #OT $OR%ING OF METALS "o&' $or(i g) 6lastic deformation of metals below the recrystalli5ation temperature is known as cold working. 2t is generally performed at room temperature. 2n some cases, slightly ele!ated temperatures may be used to pro!ide increased ductility and reduced strength. Cold working offers a number of distinct ad!antages, and for this reason !arious cold-working processes ha!e become extremely important. &ignificant ad!ances in recent years ha!e extended the use of cold forming, and the trend appears likely to continue.

2n comparison with hot working, the ad!antages of cold working are ). 7o heating is required *. ,ettter surface finish is obtained .. ,etter dimensional control is achie!ed8 therefore no secondary machining is generally needed. 0. 6roducts possess better reproducibility and interchangeablity. 1. ,etter strength, fatigue, and wear properties of material. 3. #irectional properties can be imparted. 4. Contamination problems are almost negligible. &ome disad!antages associated with cold-working processes are9 ). :igher forces are required for deformation. *. :ea!ier and more powerful equipment is required. .. %ess ductility is a!ailable. 0. etal surfaces must be clean and scale-free.

1. &train hardening occurs ( may require intermediate annealing ). 3. ;ndesirable residual stresses may be produced Cold forming processes, in general, are better suited to large-scale production of parts because of the cost of the required equipment and tooling. $arm $or(i g) etal deformation carried out at temperatures intermediate to hot and cold forming is called Warm Forming . Compared to cold forming, warm forming offers se!eral ad!antages. These include9 < %esser loads on tooling and equipment < =reater metal ductility < (ewer number of annealing operation ( because of less strain hardening ) Compared to hot forming, warm forming offers the following ad!antages. < %esser amount of heat energy requirement < ,etter precision of components < %esser scaling on parts < %esser decarburi5ation of parts

< ,etter dimensional control < ,etter surface finish < %esser thermal shock on tooling < %esser thermal fatigue to tooling, and so greater life of tooling. #ot $or(i g) 6lastic deformation of metal carried out at temperature abo!e the recrystalli5ation temperature, is called hot working. ;nder the action of heat and force, when the atoms of metal reach a certain higher energy le!el, the new crystals start forming. This is called recrystalli5ation. $hen this happens, the old grain structure deformed by pre!iously carried out mechanical working no longer exist, instead new crystals which are strain-free are formed. 2n hot working, the temperature at which the working is completed is critical since any extra heat left in the material after working will promote grain growth, leading to poor mechanical properties of material. 2n comparison with cold working, the ad!antages of hot working are ). 7o strain hardening *. %esser forces are required for deformation .. =reater ductility of material is a!ailable, and therefore more deformation is possible. 0. (a!orable grain si5e is obtained leading to better mechanical properties of material 1. /quipment of lesser power is needed 3. 7o residual stresses in the material. &ome disad!antages associated in the hot-working of metals are9 ). :eat energy is needed *. 6oor surface finish of material due to scaling of surface .. 6oor accuracy and dimensional control of parts 0. 6oor reproducibility and interchangeability of parts 1. :andling and maintaining of hot metal is difficult and troublesome 3. %ower life of tooling and equipment. Goto Home