Question no.

1
(a)
Given
Effect of strain hardening (work hardening) on sheet metal forming:
Work hardening is also known as strain hardening used for strengthening of material by
plastic deformation. The strengthening occurs because of dislocation movement within the
crystal structure of the metal, the process is generally used for the strengthening of material
with high melting point. The following diagram explains stain hardening.

Gradual deformation of crystal lattice a).movement of grain structure b).c).d) movement of

edge dislocation.

Work hardening occurs when the strain in metal is beyond the yield point, an increase in
stress produces additional plastic deformation and metal apparently become stronger and
more difficult to deform.
Work hardening has positive and negative effects on the sheet metal forming.
 Work hardening induces plastic deformation in metal, thus facilitating less energy to
produce exact shape and size.
 A slip plane containing a dislocation requires less shear stress to cause a slip than a
plane in perfect lattice.
 Although the presence of dislocation lowers the shear stress required to cause a slip,
dislocation can become entangle and interface with each other and avoided by barriers
such as grain boundaries, impurities and inclusion in metal.
Question 2
(b)
Possible method by which part could be drawn by press forming:
1. Clearance:
Clearance control is important. Because the formability of the drawn part can be
influenced by the qualities of edges on punch and die. Clearance is generally ranges
between 2-8% of sheet thickness. With the increase in clearance on both punch and
die, part can be drawn effectively.

2. Changing the die/ punch radius:

Since during the drawing process thickness of sheet is pressed at the same time. The
punch force increases rapidly and this results in the splitting of the sheet. This can be
avoided by bevelling the punch/die edges. This also reduces the noise level and makes
the operation smother.

3. Intermediate heat treatment:

Heat treatment such as hot working or cold working increases the formability limit of
the sheet metal.

4. Thicker sheet:
The increase in thickness raises the curve in formability diagram. Higher the thickness
higher the formability curves. On the other hand, in actual practice, a thick blank may
not bend as easily as around small radii without cracking.
5. Lubrication :
Lubrication at the interface between punch and the sheet metal is an important factor
in avoiding the splitting of metal sheet. With a well lubricated interface, strain in the
sheet is distributed more uniformly over the punch face.
 400

350

300 f(x) = 357.52 x − 46.64

250

200

150

100

50

0
0 0.2 0.4 0.6 0.8 1 1.2

Metallurgical technology requires materials with improved characteristics such as wear and
corrosion resistance as well as specific strength properties. Powder Metrullergy processing
produces materials of extremely fine and uniform microstructure, and enables the formulation
of materials composed of different constituents yielding unique property combinations

Properties affected by the variation in the density of structural PM

products:

PM components are designed to meet structural criteria in many applications. It is possible to

produce sintered structural or mechanical parts with properties equal to and even superior to
those of parts made by more traditional routes.

The structural performance of a PM component usually depends on several mechanical

properties either alone or in combination, for the purpose of this assignment properties
affected by the variation in density of PM product is profoundly discuss. Following are the
properties affected by the variation in density.

Corrosion resistance:
PM parts working in mechanical devices usually require no protection for corrosion because
the presence of lubricants guarantees safe operation.

However, where PM parts are exposed to high humidity or corrosive media they are more
prone to corrosion than their wrought counterparts

Corrosion resistance increases with increase in the density of the PM product. Decrease in
density results in more Surface pores. This increase the surface area exposed to the
environment and act as pockets where corrosive media have an enhanced effect.