MIN586: Metal Forming

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Dr. Shamik Basak
ha

In
.S

nd
Dr

la
Assistant Professor

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ke
Department of Mechanical and Industrial Engineering
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or
fM

Ro
Indian Institute of Technology Roorkee, India
.o

IIT
pt

Email id: shamik.basak@me.iitr.ac.in

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Metal Forming
1
 Reference books

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1. “Plasticity of Mechanical Engineers” by W.Jhonson and

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P.B.Meller, Van Nostrand.

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2. “Manufacturing Science” by A.Ghosh and A.K.Mallik.

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ha

In
3. “Metal Forming Mechanics and Metallurgy” by W.F.Hosford
.S

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Dr

la
and R.M.Caddll.

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4. “The Mathematical Theory of Plasticity” by R.Hill.
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or
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IIT
pt
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Metal Forming
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 Stress analyses

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ha

In
.S

nd
Dr

la
ca
ni

e
ha
• Stress depend on the plane on which it is acting and the

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ec
direction under consideration

or
fM

Ro
• That’s why a stress state in a point is defined
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IIT
• It is a certain number of stresses then we could defined
pt

the body under the equilibrium

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Metal Forming
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 Stress state at a point
Metal forming process involves complex stress and strain states.

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• State of stress at a point comprises the stress

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vectors or components of stress vectors acting on

st
ik
three mutually perpendicular planes passing

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m
through that point.

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In
.S • With the knowledge of there components of stress

nd
state we are able to determine normal and shear
Dr

la
stresses on any plane passing through the point.

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• Figure shows that the stress vectors Sa, Sb and Sc
ni

e
ha acting on three faces of a cubical element at a point

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P. When the side of the cubical elements are
ec

or
reduced to zero then the three faces of the cube
fM

Ro
would pass through a point.
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IIT
pt
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Metal Forming
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 Stress state at a point

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ng
k

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• The stress vectors acting on the faces of the cubical

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Ba
elements may be decomposed into stress

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st
components acting in the directions of chosen

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du
m
coordinate axes

ha

In
.S • The stress vectors acting on the faces of the cubical

nd
elements may be decomposed into stress
Dr

la
components acting in the directions of chosen

ca
coordinate axes

ni• The stress vector acting on the ABCD face is

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ha

ke
decomposed into three components,
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or
fM

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IIT
pt
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Metal Forming
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 Stress state at a point

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ng
k

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• One along the normal to the face, while other two

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Ba
are parallel to the face but are directed along the

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st
other two co-ordinate axes.

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du
m
• The three components for ABCD face can be

ha

In
.S written as, σxx, σxy and σxz .

nd
First subscript: orientation of the normal to the plane on
Dr

la
which the stress is acting

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Second subscript: gives the direction of stress component

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e
itself
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ec

or
fM

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IIT
pt
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Metal Forming
6
 Stress state at a point

g.
All the shear stresses shown in are positive. The notation given above is the one used by

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Timoshenko and most American workers in the field of elasticity

E
sa

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Ba

ri
st
ik
When dy is negligible then σxx at two different points

du
m
are same.

ha

In
Stress state at a point can be represented by these
.S

nd
manner as shown below
Dr

la
dz

ca
ni

e
ha

ke
dy
ec

or
fM

dx

Ro
Here i = the plane of which stress is acting and j =
.o

direction on which the stress is acting

IIT
pt
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Metal Forming
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 Stress state at a point

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ng
k

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sa

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Ba

ri
st
ik

du
m
dz Here i = the plane of which stress is acting and j =

ha

In
.S direction on which the stress is acting

nd
Dr

la
dy

ca
ni
dx

e
ha

ke
Diagonal element of the matrix is NORMAL STRESS COMPONENTS
ec

or
fM

Ro
All other element of the matric is SHEAR STRESS COMPONENTS
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IIT
pt

So there are NINE unknown terms as of now.

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Metal Forming
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 Stress state at a point

g.
Now, doing couple balance

ng
k

E
sa

al
Ba

ri
𝒛𝒚 𝒚𝒛

st
ik

du
m
Following, the same couple balance we can get

ha

In
.S dz

nd
𝒙𝒚 𝒚𝒙
Dr
𝒛𝒙 𝒙𝒛

la
ca
dy So the final stress matrix will be

ni

e
dx
ha

ke
ec

or
fM

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IIT
So there are SIX unknown terms for a stress matrix
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Metal Forming
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Stresses on an inclined plane

g.
Now, we determine the normal and shear stresses on any

ng
plane passing through a point at which the stress state is

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sa
known. Consider a plane ABC inclined to the three

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Ba
Cartesian co-ordinate axes x1, x2 and x3 and intersecting

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them at points A, B and C, respectively. Thus ABCP forms

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a trapezoid. The stress components acting on the three

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In
.S perpendicular faces of the trapezoid which lie in co-

nd
ordinate planes are the components of stress tensor or
Dr

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stress state at the point P and are completely known. We

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need to find the resultant stress vector S acting on the

ni
inclined plane ABC.

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ha

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The is the unit vector which can be represented as
ec

or
fM

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𝟏 𝟏 𝟐 𝟐 𝟑 𝟑
.o

Here, n1, n2 and n3 are the direction cosine of n so that

IIT
pt

𝟐 𝟐 𝟐
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𝟏 𝟐 𝟑

Metal Forming
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Stresses on an inclined plane

g.
Let, S1, S2 and S3 be the magnitudes of the three

ng
components of the vector S in the directions od co-

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sa
ordinate axes. Let ‘As’ be the area of the triangular

al
Ba
face ABC, and A1, A2 and A3 be areas of the

ri
st
triangular faces BPC, CPA and APB, respectively.

ik

du
m
ha

In
𝟏 𝟏 𝟐 𝟐 𝟑 𝟑
.S

nd
Dr

la
The trapezoid ABCP would be in equilibrium if the

ca
resultant forces along the three axes are zero.

ni
Therefore, balancing force along the three axes

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ha

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or
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IIT
pt
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Metal Forming
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Stresses on an inclined plane

g.
The area components can be written in form of unit

ng
normal vectors as follows

E
sa

al
Ba

ri
st
ik

du
m
ha

In
.S Hence substituting the above equations, it can be written

nd
as
Dr

la
ca
ni

e
ha

ke
ec
So this equation can be written as in tonsorial form as

or
fM

Ro
𝒊 𝒊𝒋 𝒋
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IIT
Here, i is the dummy index and j is the repetitive index.
pt
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Metal Forming
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 Stresses on an inclined plane

g.
The magnitude of the resultant stress vector can be denoted as

ng
k

E
sa
 
𝟐 𝟐 𝟐

al
𝟏 𝟐 𝟑

Ba

ri
st
The magnitude of normal stress acting on the inclined

ik

du
m
plane along

ha

In
.S

nd
𝟏 𝟏 𝟐 𝟐 𝟑 𝟑 𝟏 𝟏 𝟐 𝟐 𝟑 𝟑
Dr

la
𝟏 𝟏 𝟐 𝟐 𝟑 𝟑 𝒊 𝒊
Hence,

ca
ni
𝒏 𝒊 𝒊

e
ha
Hence, if we know stress at a

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ec
𝒏 𝒊𝒋 𝒋 𝒊
point we can calculate shear and

or
fM

normal stress at any arbitrary Hence the magnitude of the shear stress

Ro
plane.
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IIT  
𝟐 𝟐
pt

𝒔 𝒏
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Metal Forming
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 Principal Stresses

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• When the total stress vector on a plane is directed along the normal to the plane, the

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stress vector is called as principal stress and the plane is principal plane.

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• THERE IS NO SHEAR STRESS COMPONENTS ON A PRINCIPAL PLANE.

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• For a given stress state there is only ONE set of three principal planes and only ONE set

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of three principal stresses acting on them.

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In
.S

nd
Dr

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ca
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ha

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or
fM

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IIT
pt
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Metal Forming
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 Principal Stresses

g.
Considering again this figure, for some orientations

ng
k
of the inclined plane the shear stress component will

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sa
become zero and the total stress vector on these

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Ba

ri
planes would be directed in the direction of their

st
ik
normal. Therefore, in such cases, the stress vector

du
m
will be a scalar multiple of unit normal vector as

ha

In
.S given by the following equation.

nd
Dr

la
ca
ni
Where, is the scalar multiple or the magnitude of the vector S. Consequently, we have the

e
ha

ke
components S1-3 as follows.
ec

or
fM

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IIT
pt
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Metal Forming
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 Principal Stresses

g.
Substituting, these equations over the following set of equations,

ng
k

E
sa

al
Ba

ri
st
ik

du
m
We can rewrite as

ha

In
.S

nd
Dr

la
ca
We can write the equations in a tonsorial form as
ni

e
ha

ke
𝒊𝒋 𝒊𝒋 𝒊
ec

or
Here, is the kronecker delta function which can be written as
fM

Ro
𝒊𝒋
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𝒊𝒋 IIT 𝒊𝒋
pt
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Metal Forming
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 Principal Stresses

g.
Above equations are the homogeneous equations in n1, n2 and n3. For a non-trivial solution

ng
k
of these equations, the determinant of coefficients of the variables in the above equations must

E
sa
be zero

al
Ba

ri
st
ik
𝒊𝒋 𝒊𝒋

du
Or

m
ha

In
.S

nd
Dr

la
ca
ni

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ha

ke
This is a cubic equation and the three roots of this equation are the three principal stresses. The
ec

or
above equation, after expanding can be rewritten as
fM

Ro
.o

𝟑 𝟐
𝟏 𝟐 IIT 𝟑
pt
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Metal Forming
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 Principal Stresses

g.
Where, I1, I2 and I3 are the coefficients of this equation and have values as given below

ng
k

E
sa

al
Ba

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st
ik

du
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ha

In
Also, the I3 can be represented as the following determinant
.S

nd
Dr

la
ca
ni

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ha

ke
Since, there is only one set of three principal stresses, therefore, the cubic equation must
ec

or
remain same irrespective of the changes in the co-ordinate system, because, it has to have the
fM

Ro
same three roots. With the change of co-ordinate system, the different stress
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IIT
components change, however, the coefficients I1, I2 and I3 do not change. Hence, these
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coefficients are called as INVARIANTS of the stress tensor.

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Metal Forming
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 Principal Stresses

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This important quality of invariability of these coefficients is

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helpful in writing the constitutional equations of the materials

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Ba
behavior. The first invariant denotes that the sum of three

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st
normal stresses acting on three mutually perpendicular

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du
planes is invariant for a stress state. This sum is also equal to

m
ha

In
.S the sum of three principal stresses.

nd
Dr

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Let us denote the principal stresses by . The

ca
forces are acting as shown in Fig. In this case the stress

ni
tensors are reduced to as

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ha

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ec

or
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IIT
pt
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Metal Forming
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 Principal Stresses

g.
Prove that the principal planes are perpendicular to each other

ng
k

E
sa
We know,

al
Ba

ri
st
ik

du
m
Let us denote the principal stresses by .

ha

In
Let us consider the three set of direction cosine for three principal stresses. i.e.
.S

nd
Dr

la
ca
For . Similarly, for and for

ni

e
ha
So for first principal stress ( ) the equation set can be written as

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ec

or
(A)
fM

Ro
(B)
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IIT (C)
pt
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Metal Forming
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 Principal Stresses

g.
Prove that the principal planes are perpendicular to each other

ng
k

E
sa

al
Ba

ri
Similarly, for

st
ik

du
m
(D)

ha

In
.S (E)

nd
(F)
Dr

la
Similarly, for

ca
ni

e
ha

ke
ec

or
fM

Ro
.o

IIT
pt
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Metal Forming
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 Principal Stresses

g.
Prove that the principal planes are perpendicular to each other

ng
k

E
Now doing

sa

al
Ba
(A×y1 + B×y2 + C×y3) - (D×x1 + E×x2 + F×x3) we get

ri
st
ik

du
m
ha

In
.S

nd
Now for generalized cases,
Dr

la
Hence,

ca
That means and are perpendicular to each other.
ni
𝟏 𝟐

e
ha

ke
ec

or
Following similar way, we can prove that
fM

Ro
and are perpendicular to each other.
.o

𝟐 𝟑
IIT
pt

Hence, principal planes are perpendicular to each other. [Proved]

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Metal Forming
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 Stresses acting on OCTAHEDRAL plane

g.
ng
The octahedral plane is a plane equally inclined to directions of the three principal stresses.

E
sa
Direction cosines of normal to this plane with respect to are   .

al
   

Ba

ri
st
ik

du
,

m
ha

In
.S

nd
   
Dr

la
, ,

ca
ni
 

e
ha

ke
ec

or
𝟐 𝟎.𝟓
fM

𝟐 𝟐

Ro
𝒔,𝒐𝒄𝒕 𝟏 𝟐 𝟐 𝟑 𝟑 𝟏
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IIT
pt
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Metal Forming
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 Stresses acting on OCTAHEDRAL plane

g.
ng
By arranging the above equation,

E
sa

al
Ba
.

ri
,

st
ik

du
m
ha

In
In terms of stress invariants, it can be represented as
.S

nd
 
Dr

la
. .
,

ca
ni

e
ha
In terms of generalized stress state, it can be written as

ke
ec

or
𝟎.𝟓
fM

𝟐 𝟐 𝟐 𝟐 𝟐 𝟐

Ro
𝒔,𝒐𝒄𝒕 𝟏𝟏 𝟐𝟐 𝟐𝟐 𝟑𝟑 𝟑𝟑 𝟏𝟏 𝟏𝟐 𝟐𝟑 𝟑𝟏
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IIT
pt
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Metal Forming
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 Planes of maximum shear stresses

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ng
If we change the orientations of the inclined plane, we shall come across a set of planes on which

E
sa
the shear stresses are the maximum but normal stresses are not zero. These are called

al
Ba
planes of maximum shear stress. The direction cosines of these planes may be determined as

ri
st
given below

ik

du
m
We know already

ha

In
and
.S

nd
Hence,
Dr

la
ca
ni

e
Since is a function of ., its maxima or minima can be obtained by solving the
ha

ke
following equations.
ec

or
fM

Ro
.o

IIT
pt
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Metal Forming
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 Planes of maximum shear stresses

g.
Also we know,

ng
k

E
sa
Now

al
Ba

ri
st
ik

du
m
𝟐

ha

In
𝟐 𝟐 𝟐 𝟐 𝟐 𝟐 𝟐 𝟐 𝟐 𝟐
𝒔 𝟏 𝟑 𝟏
.S 𝟐 𝟑 𝟐 𝟑 𝟏 𝟑 𝟏 𝟐 𝟑 𝟐 𝟑

nd
Dr

la
Differentiating w.r.t

ca
ni

e
ha

ke
ec

or
fM

Ro
Rearranging
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IIT
pt
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Metal Forming
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 Planes of maximum shear stresses

g.
Similarly, Differentiating w.r.t

ng
k

E
sa

al
Ba

ri
st
ik

du
m
Rearranging

ha

In
.S

nd
Dr

la
ca
Now finally we have two set of equations

ni

e
ha

ke
𝟐 𝟐
𝟏 𝟏 𝟑 𝟏 𝟑 𝟏 𝟑 𝟐 𝟑
ec
𝟏 𝟐

or
𝟐 𝟐
fM

𝟐 𝟐 𝟑 𝟐 𝟑 𝟏 𝟏 𝟑 𝟐 𝟐 𝟑

Ro
.o

Taking as general case, IIT

pt
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Metal Forming
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 Planes of maximum shear stresses

g.
Case I: We can get, and, which gives,

ng
This plane indicates a plane where the principal stress is acting i.e. the plane of maximum

E
sa
shear stress.

al
Ba

ri
st
Case II: Again we can think that but so,

ik

du
m
Which gives, so we can get,

ha

In
   
.S

nd
Dr

la
Case III: Similarly, we can take , and    

ca
ni
Case IV: Similarly, we can take , and

e
ha    

ke
ec

or
Now show all the planes in the figure of 3D space.
fM

Ro
.o

IIT
pt
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Metal Forming
28
  
De Dr
pt .S
 
.o ha
fM m
ec ik
ha Ba
ni sa
ca k
la
IIT nd
,

Ro In
or du
,
 

ke st
e ri al
E
 

ng
Planes of maximum shear stresses

g.
 

29
Metal Forming
 De Dr
pt .S
.o ha
fM m
ec ik
ha Ba
ni sa
ca k
la
IIT nd
In
Thank you!

Ro du
or st
ke ri
e al
E ng
g.
Metal Forming
30