Metal Forming

Metal Forming
Syllabus
Unit-II
Elastic & plastic deformation
Yield criteria
Hot working v/s cold working
Analysis (equilibrium equation method) of forging process
for load estimation
with sliding friction
sticking friction and
mixed condition for slab and disc
Work required for forging
Hand, Power and Drop Forging

Elastic and Plastic Deformation

Deformation is change in original dimensions of a solid
body when it is subjected to external load.
Deformation is elastic if the original dimensions are
recovered when the load is removed.
Permanent change in dimensions due to application of
load is called plastic deformation
Most of the metal forming processes involve large
plastic deformation of the work piece.
A metal forming or a metal working operation is a
plastic deformation process in which the volume and
mass of metal are conserved and the metal is
displaced from one location to another.

 During analysis of metal forming processes, only (large) plastic

strain is considered while elastic strain is very small and can be
neglected.
The strains that result from elastic deformation are described
by Hookes law. There are similar relations for plastic
deformation, called the flow rules.

Engineering stress-strain curve

True stress-strain curve

Flow curves

a)
b)
c)
d)

Elastic plastic (power law of strain hardening)

Rigid Plastic (power law of strain hardening)
Rigid Plastic (linear strain hardening)
Rigid Ideal Plastic

Mean flow stress

Since flow stress is not constant
and it
increases with strain in cold working due to
strain hardening, it is usual practice to use
mean flow stress to calculate forming loads.
When the strain is increased from 1 to 2, mean
flow stress is defined as

Yield Criterion:
Yield criteria are mathematical descriptions of the combination of stresses
necessary to cause yielding.
OR
A yield criterion is a postulated mathematical expression of the states of stress that
will cause yielding.
Yielding in unidirectional tension test takes place when the stress = F/A reaches
the critical value.
Yielding in multiaxial stress states is not dependent on a single stress but on a
combination of all stresses.
There are two generally accepted criteria for prediction the onset of yielding in
ductile metals

Von Mises yield criterion

(Distortion energy criterion)
Tresca yield criterion
(maximum shear stress)

Tresca Yield Criterion

Yielding

occurs when the maximum shear stress

max reaches the value of the shear stress in the
uniaxial-tension test, y .
For tri-axial stress system:
(1)
Also at yielding in uniaxial tension test:
So, from (1)

--------(2)

From Tresca Yield Criterion

= .5

Von Mises yield criterion

The

von Mises criterion can be expressed

mathematically as
(2 3)2 + (3 1)2 + (1 2)2 =22 ..(1)
For pure shear,
..(2)
From (1) and (2)
= .577

From Von Mises yield criterion

.577

Therefore, from von Mises and Tresca yield criteria we

have

Tresca Yield Criterion

Von Mises yield criterion

= .5

.577

Hot Working and Cold Working: