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Module 8
Metal
forming
Structure
Process modeling
Defects
Process variation
Module 8
Module 8
Metal Forming
Metal forming includes a large group of manufacturing
processes in which plastic deformation is used to change
the shape of metal work pieces
Plastic deformation: a permanent change of shape, i.e.,
the stress in materials is larger than its yield strength
Usually a die is needed to force deformed metal into the
shape of the die
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Metal Forming
Metal with low yield strength and high ductility is in
favor of metal forming
One difference between plastic forming and metal
forming is
Plastic: solids are heated up to be polymer melt
Metal: solid state remains in the whole process
- (temperature can be either cold, warm or hot)
Module 8
Metal Forming
Metal forming is divided into: (1) bulk and (2) sheet
Bulk: (1) significant deformation
(2) massive shape change
(3) surface area to volume of the work is small
Sheet: Surface area to volume of the work is large
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Extrusion
Drawing
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Bending
Shearing
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Actually
Cutting
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Figure 1
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F/A
True strain: Instantaneous elongation per unit length of
the material
dL
L
ln
L0 L
L0
L
11
Plastic
deformation
region
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Called
FLOW
CURVE
Where
K= the strength coefficient, (MPa)
= the true strain, =the true stress
n= the strain hardening exponent,
The flow stress (Yf) is used for the above stress
(which is the stress beyond yield)
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FLOW STRESS
As deformation occurs, increasing STRESS is required
to continue deformation (shown in curve)
Flow Stress: Instantaneous value of stress required to
continue deforming the material (to keep metal
flowing)
Yf K
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k
Yf
1 n
Strength Coefficient
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Example 1:
Determine the value of the strain-hardening exponent for a
metal that will cause the average flow stress to be threequarters of the final flow stress after deformation.
According to the statement of the problem, we have
Yf 3/ 4
Yf
of
Y f 0.75Y f
K /(1 n) 0.75 K
n
1 /(1 n) 0.75
n 0.333
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Strain Rate
Speed of
deformation (could
be equal to velocity
of ram)
height of
work-piece
being
deformed
v / h
Flow Module
stress8
Y f C
m
18
Y f C
Strength
coefficient but not
the same as K
where
C strength constant
m strain-rate sensitivity exponent
Yf K
C and m are determined by the following figure
which is generated from the experiment
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Down
Up
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Even in the cold work, the strain rate could affect the
flow stress. A more general expression of the flow stress
with consideration of the strain rate and strain is
presented as follows:
Y f A
n
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Example 2:
A tensile test is carried out to determine the strength
constant C and strain-rate sensitivity exponent m for a
certain metal at 1000oF. At a strain rate = 10/sec, the
stress is measured at 23,000 lb/in2; and at a strain rate =
300/sec, the stress=45,000 lb/in2. Determine C and m
Solution:
23000=C(10)^m
45000=C(300)^m
From these two equations, one can find m=0.1973
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