1

J. Jeswiet lectures, 2005 edition. J. Jeswiet lectures, 2005 edition.

The contents of this lecture are the sole copyright of J. Jeswiet,
Professor of Mechanical Engineering.
Powerpoint format lecture J. Jeswiet 2005
Use of the contents of this lecture without the written permissi Use of the contents of this lecture without the written permissi on of the author is illegal. on of the author is illegal.
Inquiries should be addressed to: J. Jeswiet, Mechanical Engineering, McLaughlin Hall,
Queens University, Kingston, ON, Canada K7L 3N6
Fax: 613-533-6489
jeswiet@me.queensu.ca
The fine print The fine print
MANUFACTURING ENGINEERING
MECH 213
Lecture 26
Queens University, Mechanical Engineering
J. Jeswiet
Good morning. Good morning.
Topi c :
Topi c : Topi c :
Topic: forming II
2
Question set # 9 Question set # 9 - - 2005 2005
Question 1. Question 1.
Figure 16.28 (b), p 449, is a picture of a tubular shape being expanded by liquid
pressure. This is called hydroforming, which is a relati vel y new process. It can
be used to make all sorts of tubular shapes; for instance an exhaust manifold as
shown in slide 22 in lecture 22. As an aside, the hood of BMWs is formed by
hydroforming of flat sheet metal.
Assume a thin-walled tubular shape is to be hydroformed from a thin-walled
tube as shown in the figure below.
The ends are held firmly in place and high pressure liquid is forced into the
tube, up to a pressure of 10,000 psi. Once the internal pressure has reached p =
10,000 psi it starts to expand. The mean radius of the tube is 2 inches. The steel
material has a tensile yield strength,
yield
of 100,000 psi.
For purposes of estimating if a part can be made, calculate what the maximum
tube thickness, t, is, so that the tube starts to yield and expand into the cavity
that surrounds it at pressure p = 10,000 psi. Ignore strain hardening effects
once yielding has started.
Die wall
Die wall
Fluid
flow in
tube wall thickness,
t
Use the Tresca yield criteria.
Assume the maximum stress is the
hoop stress equation from question
2 in assignment 8, the previous
assignment.
Question 2 Question 2
Do question 14.25, p 398 in the textbook. [hint: use table 5.2 on page 158 to find the
yield stress for 1020.
Also calculate the true strain.
Question 3 Question 3
Do question 14.32, p 398 in the textbook. [hint: use table 6.3 on page 158 to find the
yield stress for 5052-0.
For question 14.31 the maximum force that can be exerted is 24,750 lbf
3
( ) ( ) ( ) [ ]
2
1
2
1 3
2
3 2
2
2 1
2
1
+ + =
f
Please note a correction in yesterdays notes; the von
Mises Yield criterion does not have a cubed term.
The following is correct.
Comment about last days lecture:
Metal Formed products can be found everywhere.
There are many different forming processes available
to make different shapes.
4
In most cases Dies are used in Metal Forming, In most cases Dies are used in Metal Forming,
So what is a Die? So what is a Die?
See page 373 and 376; See page 373 and 376;
open and closed die forging open and closed die forging
Flash is the excess metal or waste metal
Flashing must be cut and then ground off.
Example: connecting rod manufacture:
Example: connecting rod manufacture:
waste
See figure 14.7 See figure 14.7
5
Recalling the method of categorization:
Name
used to
describe
process
Diagram
describing
the
process
Approximate
state of stress
of process
Zone of
deformation
for process
Column 1 Column 2 Column 3 Column 4
Closed Die Forging Closed Die Forging
stress
type 9
page 376
Connecting
rods
The force needed to impression-die forge a part:
p. 377, eqn 14.2
A k F
f
=
A = projected area of the part.
Note: in this equation k is dimensionless; it is not the K in the
Holloman equation.
Closed die forging Closed die forging
8 to 12 Complex shapes without flash
5 to 8 Simple shapes with flash
3 to 5 Simple shapes without flash
Range of values for k; for equation 14.2
Table 14.2, p 378
6
stress
type 9
Coins
Coining Coining
Equation 14.2 can give an estimate of the forces required.
p. 377, eqn 14.2 A k F
f
=
The forging force, F, in open die forging of a cylinder:

+ =
h
r
r F
f
3
2
1
3


p. 375, eqn 14.1
stress
type 6
page 373
Cogging
Open Die Forging Open Die Forging.
= 0.2 is a reasonable estimate for many situations.
r = workpiece radius, h = height,
f
= flow stress, = friction
h
r
7
Now for the categorization of some other stress types
we will be looking at.
(7)
(8)
(9)
8
(12)
(7)
(8)
(8)
Drawing
Cooking
utensils
(2)
(4)
(5)
Making
beer cans
9
(2)
Bending
Eave
troughs
Cutting & Shearing
Car door
panels
10
(10)
(10)
(11)
(11)
Cutting
Making holes in
sheet metal
See textbook p 1258
11
Metal Forming processes
Enlarging the forming process:
The end result end result of the
manufacturing
process, from design
to production is a is a
product, product, such as a
gearbox
Parts which can
be forged and
machined are:
12
In all of the foregoing,
speed, temperature, tolerance and surface finish
play an important rle
Also, there are both independent and dependent variables which
have an effect upon each of the foregoing processes
Metal Forming Process Variables Metal Forming Process Variables
Independent variables:
aspects of a process over which an engineer has direct
control and which are specified when setting up the process.
Dependent variables:
variables which are the result of the process and cannot be
controlled directly.
Independent variables in Metal Forming
stuff we control
Independent variables in Metal Forming
stuff we control
1. Material
2. Starting geometry
3. Tool and Die geometry
4. Lubrication
5. Speed of operation
6. Starting temperature
7. Amount of deformation
Dependent variables
Dependent variables
1. Force and Power requirements
2. Material properties of the product
3. Exit temperature
4. Surface finish
5. Nature of material flow during forming
13
Note:
The rate at which deformation takes place rate at which deformation takes place is of concern,
especially in hot working hot working.
Strain-rate Sensitivity
Strain-rate Sensitivity
All the foregoing does not take into account the
rate at which the material rate at which the material is being deformed.
Developing models which can be used to calculate forging loads
is an ongoing problem for many Engineers.
In the next lecture, a simple model will be developed for Open
Die Forging.
Equations 14.1 and 14.2 give approximations for loads.
They do not give any insight into what is happening. Models are
developed for this purpose.
Many rules of thumb or rough approximations have been
developed to give a good idea what the loads will be.
14
Thank you for your attention
Thank you for your attention