Forming 3

Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

1
Forging Analysis - 2
ver. 1
Singh/ Dr. Colton
2
Overview
Slab analysis
frictionless
with friction
Rectangular
Cylindrical
Strain hardening and rate effects
Flash
Redundant work
Singh/ Dr. Colton
3
Forging cylindrical part
sliding region
h
p
Singh/ Dr. Colton
4
Equilibrium in r direction
( ) ( )
d h dr r d
d
dr h
dr d r p d r h dF
r r
r r
+ + +
= =
2
2
2 0
neglecting HOTs
0 2 = +
r r
d hr dr h dr h dr pr

2 2
sin
d d
=
|
.
|
\
|
N.B.
Singh/ Dr. Colton
5
Axisymmetric flow and yield
For axisymmetric flow
By Tresca
flow flow r
k p 2 2 = = = +
dp d
r
=
p
r
flow
/2 =
flow
( )

= =
=
+
= =
r r
r
r
dr
r
r dr r
r
dr
;
2
2 2
;
Singh/ Dr. Colton
6
Stress in z direction
dp hr dr pr = 2
0 2 = + + dp hr dr h dr h dr pr
r r

substituting
or
rearranging
dr
h p
dp 2
=
Singh/ Dr. Colton
7
Forging pressure - sliding
dr
h p
dp
R
r p
flow
r
=

2
2
( )
(
= r R
h
p
flow
r

2
exp
2
for r
k
< r < R
Singh/ Dr. Colton
8
Average forging pressure
sliding
( ) ( )
( ) dr r r R
h r R
dr r
p
r R
p
R
r
k
R
r
flow
r
k flow
ave
k k

(

2
exp
2
2
2
1
2
2 2 2 2
( )
R
r
k flow
ave
k
h
r
h
r
h
R h
r R
p
)
`
|
.
|
\
|

|
.
|
\
|

|
.
|
\
|
|
|
.
|
\
|
= 1
2 2
exp
2
exp
2
2
2
2
2 2

( )
)
`
|
.
|
\
|

|
.
|
\
|

|
.
|
\
|

|
.
|
\
|

|
.
|
\
|
|
|
.
|
\
|
= 1
2 2
exp 1
2 2
exp
2
exp
2
2
2
2
2 2
h
r
h
r
h
R
h
R
h
R h
r R
p
k k
k flow
ave

Singh/ Dr. Colton
9
sliding
( )
( )
(

|
.
|
\
|
|
.
|
\
|
+
|
.
|
\
|

|
|
.
|
\
|
= 1
2
1
2 2
exp
2
2
2
2
2 2
h
R
h
r
h
r R h
r R
p
k k
k flow
ave

Singh/ Dr. Colton
10
Forging force sliding
( )
2 2
k ave ave forging
r R p A p F = =
( )
( )
2 2
2
1
2
1
2 2
exp
2
4
k
k k
flow forging
r R
h
R
h
r
h
r R
R
h
F
(

|
.
|
\
|
|
.
|
\
|
+
|
.
|
\
|

|
|
.
|
\
|
=


Singh/ Dr. Colton
11
Taking the first four terms of a Taylors
series expansion for the exponential
about 0 for
all sliding approximation (r
k
= 0)
1 x
yields
( )

=
= + + + + + =
n
k
k n
k
x
n
x x x
x x
0
3 2
! ! ! 3 ! 2
1 exp L
(
|
.
|
\
|
+ =
h
R p
flow
ave
3
2
1
2


Singh/ Dr. Colton
12
Forging force
all sliding approximation
2
3
2
1 2 R
h
R
F
flow forging

|
.
|
\
|
+ =
2
R p A p F
ave ave forging
= =
Singh/ Dr. Colton
13
Transition sticking / sliding
Set
flow
= p and solve for r
k
(
|
.
|
\
|

=
h
r R p
k
flow

2 exp
2
(
|
.
|
\
|

=
h
r R
p
p
k
2 exp
2
|
.
|
\
|

=
|
|
.
|
\
|
h
r R
k
2
2
1
ln
|
|
.
|
\
|
=
2
1
ln
2
h
R r
k
Singh/ Dr. Colton
14
Forging pressure - sticking
region
Use the same method as for sliding
Substitute p =
flow
,
Assume Tresca yield criterion
dr
h
dp
flow
2
=
dp hr dr pr = 2
dp hr dr r
flow
= 2
Singh/ Dr. Colton
15
region
dr
h
dp
r
r
flow
p
p
k
r
k
r

=
2
( )
k
flow
r r
r r
h
p p
k
=
2
( )
h
r r
p p
k
flow
r r
k

=
2
Singh/ Dr. Colton
16
region
( )
( )
h
r r
r R
h
p
k
k
flow
r

+
(
2
exp
2
for 0 < r < r
k
p
r
k
determined from sliding equation
( )
(
=
k
flow
r
r R
h
p
k

2
exp
2
Singh/ Dr. Colton
17
Average forging pressure -
sticking
( ) rdr
h
r r
r R
h r
dr r p
r
p
k k
r
k
k
k
r
r
k flow
ave
|
.
|
\
|
+
(
= =

0
2
0
2
2
exp
2
2
1
2

( ) dr r
h h
r r
r R
h
r
r
p
k
r
k
k
k flow
ave
|
.
|
\
|

+
(
=

0
2
2
1 2
exp
2
2

( )
k
r
k
k
k flow
ave
h
r
h
r r
r R
h
r
r
p
0
3 2 2
2
3 2
2
exp
2
2
2
|
|
.
|
\
|

+
(

Singh/ Dr. Colton
18
Average forging pressure - sticking
( )
|
|
.
|
\
|
+
(
=
h
r
h
r
r R
h
r
r
p
k k
k
k
k flow
ave
3 2
2
exp
2
2
2
3 3 2
2

( )
|
.
|
\
|
+
(
=
h
r
r R
h
p
k
k
flow
ave
3
2
exp
2

( )
k
r
k
k
k flow
ave
h
r
h
r r
r R
h
r
r
p
0
3 2 2
2
3 2
2
exp
2
2
2
|
|
.
|
\
|

+
(

Singh/ Dr. Colton
19
Forging force sticking region
2
k ave ave forging
r p A p F = =
( )
2
3
2
exp 2
k
k
k flow forging
r
h
r
r R
h
F
|
.
|
\
|
+
(

Singh/ Dr. Colton
20
Sticking and sliding
If you have both sticking and sliding, and you
cant approximate by one or the other,
Then you need to include both in your
pressure and average pressure calculations.
( ) ( )
sticking
ave
sliding
ave forging
A p A p F + =
sticking sliding forging
F F F + =
Singh/ Dr. Colton
21
Strain hardening
(cold - below recrystallization
point)
n
flow
K Y = = 2
Tresca
Singh/ Dr. Colton
22
Strain rate effect
(hot above recrystallization point)
Tresca
( )
m
flow
C Y
&
= = 2
height ous instantane
velocity platen
h
v
dt
dh
h
1
= = =
&
Singh/ Dr. Colton
23
Flash for closed die forging
(plane strain)
Say we have a typical flash with
thickness h/20 and length w/4
w
w/4
h/20
h
Singh/ Dr. Colton
24
in forging (Tresca)
in flash (Tresca)
|
.
|
\
|
+ =
h
w
p
flow ave
2
1 2

|
.
|
\
|
+ =
h
w
p
flow ave

5
1 2
Singh/ Dr. Colton
25
Flash
Flashs high deformation resistance results
in filled mold
Process wouldnt work without friction
Singh/ Dr. Colton
26
Deformation Work
In general, work done in bulk deformation processes
has three components
Total work, W= W
ideal
+ W
friction
+ W
redundant
Work of ideal plastic deformation, W
ideal
= (area under true stress-true strain curve)(volume)
= (volume)
For a true stress-true strain curve :
|
|
.
|
\
|
t t
d
t

0
n
t t
K =
( ) ( )
t f
n
t
ideal
Y
n
K
W
volume
1
volume
1
=
|
|
.
|
\
|
+
=
+
stress flow Avg. =
f
Y
Singh/ Dr. Colton
27
Deformation Work
Friction between dies and workpiece
causes inhomogeneous (non-uniform)
deformation called barreling
Barreling
Effect
Frictional Forces
Singh/ Dr. Colton
28
Deformation Work
Internal shearing of material requires
redundant work to be expended
Ideal Deformation
Redundant Deformation
Singh/ Dr. Colton
29
Redundant Zone
Singh/ Dr. Colton
30
Closed/Impression Die Forging
Analysis more complex due to large
variation in strains in different parts of
workpiece
Approximate approaches
Divide forging into simple part shapes e.g.
cylinders, slabs etc. that can be analyzed
separately
Consider entire forging as a simplified shape
Singh/ Dr. Colton
31
Steps in latter analysis approach
Step 1: calculate average height from
volume V and total projected area A
t
of
part (including flash area)
Step 2:
Lw
V
A
V
h
t
avg
= =
|
|
.
|
\
|
= =
avg
i
avg
h
h
ln strain avg.
avg
avg
h
v
= = rate strain avg.
&
Singh/ Dr. Colton
32
Step 3: calculate flow stress of material Y
f
for cold/hot working
Step 4:
K
p
= pressure multiplying factor
= 3~5 for simple shapes without flash
= 5~8 for simple shapes with flash
= 8~12 for complex shapes with flash
t f p avg
A Y K F = = load forging Avg.
Singh/ Dr. Colton
33
Other Analysis Methods
Complex closed die forging simulated
using finite element software
Source: http://nsmwww.eng.ohio-state.edu/html/f-flashlessforg.html
Singh/ Dr. Colton
34
Upper Bound Theorem
Any estimate of the collapse load of a
structure made by equating the internal
rate of energy dissipation to the rate at
which external forces do work in some
assumed pattern of deformation will be >
or = to the correct load.
Singh/ Dr. Colton
35
Upper Bound Theorem
Assumptions
Isotropic and homogeneous
Neglect strain hardening and strain rate
Frictionless or constant shear stress
condition exists at tool-work piece
interface
2-D, plane strain with all deformation
occurring by shear on a few planes.
Elsewhere, material is rigid.
Singh/ Dr. Colton
36
Upper Bound Theorem
k = shear flow stress
S
i
= length of shear plane
V
*
= velocity of shear
=
n
i
i i
V kS
dt
dW
1
Singh/ Dr. Colton
37
Upper Bound Theorem
Indentation of a plate (slip-line analysis)
w
L
F
h =
p
A
B C
D
C
A D
v
o
v
BA
v
CA
v
DC
v
BC
Singh/ Dr. Colton
38
Work, shearing force
Work is done by shearing
along AB, BC, AC, and CD.
Lengths calculated from figure
at right.
Shearing force along any
boundary, per unit length, w,
is k (shear yield stress)
times the length of the
boundary, L.
A
B
C
D
C
A
D
Singh/ Dr. Colton
39
Shearing velocities
v
o
v
BA
v
CA
v
DC
v
BC
2
2
2
o
DC
o
CA
o BC
o BA
v
v
v
v
v v
v v
=
=
=
=
Singh/ Dr. Colton
40
Motions
Singh/ Dr. Colton
41
Total power delivered
each term has been counted twice
due to symmetry
Simplifying
p = 6k
|
|
.
|
\
|
+ + + =
2 2
2
2
2
0 o o
o o
Lv Lv
Lv
Lv
k Lpv
Singh/ Dr. Colton
42
Total power delivered
p = 6k
using von Mises
hence
Y
Y
k = = 577 . 0
3
Y
Y
p = = 46 . 3
3
6
Singh/ Dr. Colton
43
Exact solution
p = 5.14 k = 2.97 Y
Solution above
p = 6 k = 3.46 Y
so we can see the effect of constraint
redundant work: higher pressure
Singh/ Dr. Colton
44
Non-homogeneous deformation
and Redundant work
If the slab is thick or friction:
non-homogeneous deformation
redundant work
If the slab is thin or unconstrained:
(e.g., open die forging without friction)
no redundant work
Singh/ Dr. Colton
45
Indenting at h/L =1
L
h
F
F
v
1
v
1
v
o
v
o
A
B
C
E
v
1
v
1
v
o
v
o
v
CE
v
BC
Singh/ Dr. Colton
46
v
1
v
1
v
o
v
o
A
B
C
E
2
L
CE BC = =
o CE BC
v v v = = 2
v
1
v
1
v
o
v
o
v
CE
v
BC
2
2 2
2
2 kL
v
L pv
o
o
=
Analysis - power delivered
p = 2k = 1.15 Y (plane strain result)
Singh/ Dr. Colton
47
Redundant work limit ( = h/L)
(plane strain)
h/L < 1: no redundant work
p = 1.15 Y
1 < h/L < 8.7: some redundant work
1.15 Y < p < 2.97 Y
h/L > 8.7: redundant work
same as infinite plate
p = 2.97 Y
Singh/ Dr. Colton
48
Redundant work correction
factor (Q
r
)
Can be characterized by:
p = Q
r
Y
or
Q
r
= p/
y
= p/2
y
(by Tresca)
where Q
r
= correction factor for redundant
work
Singh/ Dr. Colton
49
Redundant work factor
(Backofen)
(frictionless)
Q
r
=
Singh/ Dr. Colton
50
Redundant work factor
(Kalpakjian) -
(friction)
Singh/ Dr. Colton
51
Summary
Slab analysis
frictionless
with friction
Rectangular
Cylindrical
Strain hardening and rate effects
Flash
Redundant work

Forming 3

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Forming 3

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Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

Prof. Ramesh Singh, Notes by Dr.

Prof. Ramesh Singh, Notes by Dr.

Prof. Ramesh Singh, Notes by Dr.

Prof. Ramesh Singh, Notes by Dr.

Prof. Ramesh Singh, Notes by Dr.

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