Fundamentals

of
Metal Forming
ME 482 - Manufacturing Systems

FundamentalsofMetalForming
BulkdeformationvsSheetmetalworking
Bulkdeformation

Aluminum extrudate a simple angled shape.

The die shown is more complex.

*Lowsurfaceareatovolumeratios
*Operationsincreasesurfaceareatovolumeratios
Operationsare:
This group of machines - which are over a
half mile long - roll the slab into sheet steel
using tremendous pressure.

rolling

extrusion

forging

drawing

ME 482 - Manufacturing Systems

FundamentalsofMetalForming
Bulkdeformation
Rollingcharacteristics

*compressivedeformation
*2ormorerolls
*strongfrictionalrelationship
Extrusioncharacteristics
*compressivedeformation
*forcemetalthroughdieopening
*strongfrictionalrelationship
*hotandcoldworkingprocess
ME 482 - Manufacturing Systems

FundamentalsofMetalForming
Sheetmetalworking
Characterizedby:
*largesurfaceareatovolumeratios
*littleratiochangeafterprocess
*machinescalledpresses
*partscalledstampings
*toolsarepunchanddie
Operations:
bending
ME 482 - Manufacturing Systems

drawing

shearing

MaterialBehaviorFlowStress
=K n
Conceptofflowstress,Yftheinstantaneousstress
requiredtodeformthematerial
Yf=K n
Processforceconsiderations:
*duringcompression,determineinstantaneousforcefromYf
*maxforceisoftenallthatisrequired,typicallyatendofstroke
*forceanalysismaybebasedonaveragestressesandstrains

Averageflowstress=Yf=K n/(1+n)
ME 482 - Manufacturing Systems

FundamentalsofMetalForming
TemperatureandMetalForming
Kandndependonworkingtemperature,characterizedby
3ranges:

Coldworking

Warmworking

Hotworking

ME 482 - Manufacturing Systems

FundamentalsofMetalForming

TemperatureandMetalFormingcoldworking

Advantages:
*goodaccuracyandtolerances
*bettersurfacefinish
*strainhardeningincreasesstrengthandhardness
*directionalproperties
*energyeconomy

Disadvantages:
*higherforces/power
*strainhardeninglimitsdeformation
*mayneedtoanneal
ME 482 - Manufacturing Systems

FundamentalsofMetalForming
Temperatureand
MetalFormingwarmworking
Temperature
Advantages:
*aboveroomtemp.,butbelowrecrystallizationtemp.(0.3Tm)
*lowerforcesandpower
*reducedstrainhardening
*moredifficultgeometry
*noneedforannealing

Disadvantages:
*moreenergy
*limitedgeometry

ME 482 - Manufacturing Systems

FundamentalsofMetalForming
TemperatureandMetalForminghotworking
Advantages:
*aboverecrystallizationtemp.(0.5Tm<T<0.75Tm)
*lowerforcesandpower
*nostrainhardening
*difficultgeometry
*isotropicproperties

Disadvantages:
*moreenergy
*poorersurfacefinish
*shortertoollife
ME 482 - Manufacturing Systems

Flow stress

FundamentalsofMetalForming

StrainRate
Room temp.

Note:Strainrateastrongfunctionofworkingtemperature

v

h

where

400 C

1
(highvalues>1000s
)
800 C

1200 C
v=speedoftestinghead
h=instantaneousheightofpartbeingworked
We will mostly assume that
strain rate is negligible at
10 temperature!
102 103 104
room
m 1.0
Strainrateequation: Yf=C0.1

Strain rate

C=strengthconstant
m=strainratecoefficient
ME 482 - Manufacturing Systems

Frictionandlubrication
Friction:
*undesirable
*retardsmetalflow(residualstresses&defects)
*increasesforceandpowerrequirements
*wearstooling
Lubricants are usually oil-based, and when
*hightemperaturestiction
used in extreme pressure situations, sulfur,

Lubricants:

chlorine and phosphorus in the lubricant

may chemically react with the metal
surfaces (tool, chip). The reactions form a
surface boundary layer that is more
effective than the lubricant itself in
reducing friction. Lubricants are most
effective at cutting speeds < 400 ft/min.

*reducefrictionaleffects
*removeheatandmaterial
*lengthentoollife
*mayreactchemicallywithtoolorwork
*concernsabouttoxicity,flammability.(mineraloils,
emulsions,oils,graphite,glass..)
ME 482 - Manufacturing Systems

Example20.6
ForametalwithK=50,000lb/in2andn=0.27,determine
theaverageflowstressthatthemetalexperiencesifitis
subjectedtoastressthatisequaltoitsstrengthcoefficientK.
Solution:
Yf=K=50,000=50,000 n
Thus=1
Yf=50,000(1)0.27/1.27=39,370lb/in2
ME 482 - Manufacturing Systems

Whathaveyoulearned?

ME 482 - Manufacturing Systems