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01 - Fundamentals of Metalworking
01 - Fundamentals of Metalworking
Fundamentals of
metalworking
Subjects of interest
Introduction/objectives
Classification of metal processes
Mechanics of metalworking
Flow curves
Effects of temperature on metalworking
- Hot working
- Cold working
Effects of metallurgical structure on forming processes
Effects of speed of deformation on forming processes
Effects of friction and lubricant
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Objectives
This chapter provides classification of metal forming
processes based on types of forces applied onto metals.
Mechanics of metal forming will be outlined to understand
stress criterion for plastic deformation.
Differences between hot and cold working will be highlighted
and advantages-disadvantages of hot and cold working will be
given.
Effects of deformation speed and friction on metal working
process will be included.
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Direct-compression-type processes
Indirect-compression processes
Tension type processes
Bending processes
Shearing processes
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Direct-compression
type processes:
the applied force is normal to
the direction of the metal flow
in compression, i.e., forging
and rolling processes.
Indirect-compression type processes:
the primary forces are frequently tensile, with indirect compressive
forces developed by the reaction of the work piece. The metal flow is
therefore under the combined stress state, i.e., extrusion, wiredrawing,
tube drawing.
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Bending processes:
the applied force involves the
application of bending moments
to the sheet.
Shearing processes:
the applied force involves the
application of shearing forces of
sufficient magnitude to rupture the
metal in the plane of shear.
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Compressive
forming
Combined tensile
and compressive
forming
Tensile
forming
Forming by
bending
Bending with
linear tool
motion
Rolling
Stretching
Deep drawing
Expanding
Flange forming
Recessing
Indenting
Spinning
Upset bulging
Bending with
rotary tool
motion
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Forming by
shearing
Joggling
Twisting
Blanking
Coining
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ho
1 + 2 + 3 = 0
Deformation
h1
Eq. 1
dh
h
h
= ln 1 = ln o , ho > h1
h
ho
h1
ho
Eq. 2
h1 ho h1
e=
= 1
ho
ho
Eq. 3
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ho
ho h1
h1
c = ln , ec =
= 1
h1
ho
ho
And the fractional reduction
(reduction of area) in metal working
deformation is given by
Ao A1
r=
Ao
A1 L1 = Ao Lo
Ao
A1
Eq. 4
Eq. 5
A1
A1
r = 1
or
= 1 r
Ao
Ao
Lo
L1
Ao
L1
1
= ln = ln = ln
Lo
A1
1 r
Eq. 6
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e=
= ln
r=
L2 L1 2 L1 L1
=
= 1. 0
L1
L1
e=
A1 A2
A
L
L
= 1 2 = 1 1 = 1 1 = 0. 5
A1
A1
L2
2 L1
L1 / 2 L1
L L /2
= 0.5 or ec = 1 1 = 0.5
L1
L1
L1 / 2
1
= ln
= ln = ln 2 = 0.693
L1
2
r = 1
L2
2L
= ln 1 = 0.693
L1
L1
L1
= 1.0
L1 / 2
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F
A
=
F
F
A
Eq. 7
Uniaxial stress
Yielding in multiaxial
stress states is not
dependent on a single stress
but on a combination of all
stresses.
Von Mises yield criterion
(Distortion energy criterion)
Tresca yield criterion
(maximum shear stress)
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Triaxial stresses
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[(
2
2
2
2
)
+
(
)
+
(
)
=
6
k
1
2
2
3
3
1
Eq. 8
2 = 6k , then k =
2
o
Eq. 9
Substituting k from
( 1 2) 2 + ( 2 3 ) 2 + ( 3 1 ) 2
Eq.9 in Eq.8;
1
2
Eq. 10
= 2 o
y = 0.577 o
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Eq. 11
***
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max =
1 3 = o
In pure shear, 1 = -3 = k , 2 = 0,
max = y
y = 0.5 o
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=o =
o
2
Eq.12
Eq.13
***
Eq.14
Jan-Mar 2007
y = 0.577 o
***
y = 0.5 o
***
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FEM analysis
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Flow curves
Flow curve indicates whether metal is readily deformed at given
conditions, i.e., strain rate, temperature.
Flow curve is strongly dependent on strain rate and
temperature.
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= Kn
is ture stress
is true strain
K is constant
n is work hardening exponent
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Flow curve
Flow curve
True stress
True stress,
10
20
30
40
50
True strain,
Temperature
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Flow stress
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Flow curve
Strain hardening occurred when an iron wire had been
drawn to a specific true strain.
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Working processes
The methods used to mechanically shape metals into other
product forms are called Working Processes.
Working processes
Hot working
T ~ 0.6
0.60.8T
0.8 m
Cold working
T 0.3T
0.3 m
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www.magnesiumextrusions.com
Magnesium bars
Steel plates
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Hot working
Hot working involves deformation at temperatures where
recrystallisation can occur (0.6-0.8 Tm).
Examples of hot working temperatures for each metal
Metal
Melting point
(oC)
Recrystallisation
temperature
(oC)
Hot working
range
(oC)
Iron
1535
450
900-1200
Copper
1083
200
650-900
Aluminium (alloys)
660
150
350-500
Zinc
420
20
110-170
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Ductility
Strength
Hardness
Recovery
~0.3Tm
Temperature
New grains
Recrystallisation
~0.5Tm
Grain growth
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www.msm.cam.ac.uk
Recrystallisation
Deformed matrix
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Aluminium sheet
Critical
deformation
5
10
15
20
25
Plastic deformation, %
The greater the driving force (greater prior plastic deformation),
the greater the number of nuclei that will form and the finer will
be the final grain size.
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Properties
Ductility
Strength
Grain size
Small grains make dislocations more difficult to move
More slip plane, therefore, greater ductility
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Temp
Flow stress
Strain rate
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Flow stress
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Grain growth
Mechanical
property
deterioration
Ductility
Formability
Result in an increase in
average grain diameter.
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Recovery
Recovery is a thermally activated process, which results in
lower density of dislocations or rearrangement of dislocation
structure (as a consequence of strain hardening during
deformation process).
Recovery process includes
annihilation of dislocation,
polygonization of dislocation,
dislocation climb.
Certain amount of stored
energy is released during
annealing without an obvious
change in optical microstructure.
Polygonization
www.esrf.fr
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Note:
Static recrystallisation
Static recovery
During cooling
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Cold working
Normally performed at room temperature but in general < 0.3Tm,
where recovery is limited and recrystallisation does not occur.
Work hardening occurs (strength and hardness increase but
ductility decreases).
The extent of deformation is rather limited if cracks are to be
avoid, therefore intermediate anneals that enable recrystallisation
are frequently used afterwards.
The materials suitable for cold working should have a relatively
low yield stress and a relatively high work hardening rate
(determined primarily by its tensile properties).
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Disdvantages
Use high amount of deformation due to low operating temperatures,
therefore, require soft materials.
Equipment (rolls, dies, presses) is big and expensive.
Reduced ductility, therefore, require subsequent annealing treatments.
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Mechanical
properties
Hot rolled
Cold rolled
Ultimate tensile
strength, TS
(MPa)
427
558
Yield stress, y
(MPa)
220
345
Brinell hardness
(HB)
94
174
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Increasing reduction
Rolling direction
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Working
direction
microcrack
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Triaxial stresses
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Note:
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F i Ar i
= =
=
P pAr
p
Eq.15
Where
= frictional coefficient
= the shearing stress at the interface
P = the load normal to the interface
F = the shearing force
Ar= summation of asperity areas in contact
p = the stress normal to the interface
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Where
= frictional coefficient
= the shearing stress at the interface
p = the stress normal to the interface
Deformation pressure in compression as a function
of u and a/h.
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X=a
Pmax
P
Friction hill
h
o
-a
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Workability
Workability is concerned with the extent to which a material
can be deformed in a specific metal working process without
the formation of cracks.
1. Cracks at a free surface
Cracks which occur in metal
2. Cracks that develop in a surface
working processes can be
where interface friction is high
grouped into three broad
3. Internal cracks.
categories:
Jan-Mar 2007
References
Dieter, G.E., Mechanical metallurgy, 1988, SI metric edition,
McGraw-Hill, ISBN 0-07-100406-8.
Edwards, L. and Endean, M., Manufacturing with materials,
1990, Butterworth Heinemann, ISBN 0-7506-2754-9.
Lange, K., Handbook of metal forming, 1985, R.R Donnelly &
Sons Company, ISBN 0-07-036285-8.
Lecture notes, Birmingham, UK, 2003
Metal forming processes, Prof Manus
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