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Forming 2 PDF
Forming 2 PDF
ver. 1
unit depth
into figure
y
h
x
dx
τf
p
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Force balance in x-direction
hdσ x + 2τ friction dx = 0
2τ friction
dσ x = − dx
h
k
Mohr’s circle
2 p σx
σ x + p = 2k = σ flow = 1.15 ⋅ σ flow
3
(distortion energy (von Mises) criterion, N.B. all done on a per
plane strain) unit depth basis
d (2k ) = d (σ x + p ) ∴ dp = − dσ x
2τ friction 2τ friction
dσ x = − dx ∴ dp = dx
h h
noting: τfriction = µp
2µ dp 2 µ
dp = pdx = dx
h p h
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Sliding region
px
2µ
x
dp
∫2k p = ∫0 h dx
p x 2 µx 2 µx
= 1 + p x = 1.15 ⋅ σ flow ⋅ 1 +
2k h h
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Average forging pressure –
all sliding approximation
• using the Taylor’s series approximation
w w w
2
px 2 µx
2 2 µx 2
2
∫
pave 0 2k
dx ∫ 1 +
0
dx x +
h 2h 0
= = =
2k w w w
2 2 2
pave µw
= 1 +
2k 2h
µw N.B done on a
pave = 1.15 ⋅ σ flow ⋅ 1 + per unit depth basis
2h
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging force –
all sliding approximation
F forging = pave ⋅ width ⋅ depth
µw
F forging = 1.15 ⋅ σ flow ⋅ 1 + ⋅ w ⋅ depth
2h
sliding
region
sticking
region
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Sliding / sticking transition
• Transition will occur at xk
• using k = µp, in:
px 2 µx k 2 µxk
= exp = exp
2k h 2 µk h
• hence:
xk 1 1
= ln
h 2µ 2µ
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Sticking region
2µ
dp = pdx
h
• Using p = k/ µ
2µ k
dp = dx
h µ
px x
2k 2k
∫p dp = x∫ h dx p x − p xk = ( x − xk )
kx k
h
• and xk 1 1
= ln
h 2µ 2µ
px 1 1 x
= 1 − ln
+
2k 2 µ 2 µ
h
1 1 x
p x = 1.15 ⋅ σ flow ⋅ 1 − ln +
2 µ 2 µ h
∆p
pedge
0
x=0 x=w/2
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging pressure –
all sticking approximation
pedge = 2k
px x
2k 2k
∫2k dp = ∫0 h dx p x − 2k = (x )
h
px x
∴ = 1 +
2k h
x
p x = 1.15 ⋅ σ flow ⋅ 1 +
h
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Average forging pressure –
all sticking approximation
w w w
2
px x2 x
2 2
∫
pave 0 2k
dx ∫ 1 + dx
0
h
x +
2h 0
= = =
2k w2 w2 w2
pave w
= 1 +
2k 4h
w
pave = 1.15 ⋅ σ flow ⋅ 1 +
4h
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging force –
all sticking approximation
w
F forging = 1.15 ⋅ σ flow ⋅ 1 + ⋅ w ⋅ depth
4h
σ flow = Y = Kε n
σ flow = Y = C (ε& ) m
1 dh v platen velocity
ε& = = =
h dt h instantaneous height
• hf = 0.25”, µ = 0.25 1”
• Show effect of friction on total forging force.
• Use the slab method.
• Assume it doesn’t get wider in 36” direction.
• Assume cold forging.
2 µx
px = 1.15 ⋅ σ flow ⋅ exp
h
f
= 1150 ⋅ exp(2 x )
1 1 x
p x = 1.15 ⋅ σ flow ⋅ 1 − ln +
2 µ 2µ h f
= 1150 ⋅ (0.6 + 4 x )
10000
8000 xk
xk
6000
4000 P(sticking)
2000 P(sliding)
0
0 0.5 1 1.5 2 2.5 3 3.5 4
Distance from forging edge (in)
Force = ∫∫ p ⋅dA
xk w/ 2
F forging = 2 ∫ p x dx .depth + 2 ∫ p x dx .depth
0 x
sliding k sticking
h 2 µxk
exp − 1
2µ h
=
(xk − 0)
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-12
Substituting values
sliding
pave 0.25 2 × 0.25 × 0.347
exp − 1
1.15σ flow 2 × 0.25 0.25
= = 1.44
unit depth (0.347 − 0)
sticking
pave 1 1 4 1 42 2
1 − ln − 0.347 + − 0.347
1.15σ flow 2 × 0.25 2 × 0.25 2 2 × 0.25 4
=
unit depth 4
− 0.347
2
= 5.3
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-10
Sticking next
w
pave 1
2
1 x
1.15σ flow
∫x 2µ 1 − ln 2µ + h dx
= k
unit depth w −x
2 k
w
1 2
1 x2
1 − ln ⋅ x +
2µ 2µ 2h
=
w −x
2 k
xk
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton
Forging - Ex. 1-11
pave
1.15σ flow
1
1 − ln
2µ
1 w
(
2 − xk +
2µ
1 w2
2h 4
)2
− xk
=
unit depth w −x
2 k
F
unit depth
(
= 1.15σ flow ( pave ⋅ A)sliding + ( pave ⋅ A)sticking )
F
= 1150 × ((1.44 × 0.69 ) + (5.3 × 3.31))
unit depth
= 21,110 lb / inch
F wf
= 1.15σ flow ⋅ w f ⋅ 1 +
unit length 4h
f
4
= 1150 ⋅ 4 ⋅ 1 +
4 ⋅ 0.25
= 23,000 lb / inch depth
w
F forging = 1.15 ⋅ σ flow ⋅ 1 + ⋅ w ⋅ depth
4h
F(all sticking) = 828,000 lbs = 414 tons
µw
F forging = 1.15 ⋅ σ flow ⋅ 1 + ⋅ w ⋅ depth
2h
mu=0
20000 mu=0.1
mu=0.2
15000 mu=0.25
depth)
mu=0.3
10000 mu=0.4
mu=0.5
5000
0
0 0.2 0.4 0.6 0.8
Stroke (in)
15000
10000
5000
0
0 0.1 0.2 0.3 0.4 0.5 0.6
Friction coefficient