Bulk Forming Processes (II)

Prof. Dr. Melik DÖLEN

Middle East Technical University

Department of Mechanical Engineering

3/23/2020 ME 303 - Section 03b 1

 Content
 Extrusion and Drawing
 Classification of Drawing
 Forward Rod Extrusion Force
 Backward Can Impact Extrusion
Force
 Empirical Force Calculation
 Extrusion
 Drawing
 Piercing
 Examples

3/23/2020 ME 303 - Section 03b 2

 Classification of Extrusion
1. Reducing: Rods, Tubes.
2. Extrusion
a. Extrusion with rigid tools
i. Forward (direct): Rods, Tubes.
ii. Backward: Rods, Tubes.
iii. Transverse: Rods, Tubes.
b. Extrusion with non-rigid tools
i. Hydrostatic forward: Rods.
3. Impact Extrusion
a. Impact extrusion with rigid tools
i. Forward (direct): Rods, Tubes, Canes.
ii. Backward: Rods, Tubes, Canes.
iii. Transverse: Rods, Tubes.
b. Impact extrusion with non-rigid tools
i. Hydrostatic forward: Rods, Tubes.

3/23/2020 ME 303 - Section 03b 3

 Extrusion
Forward Rod Extrusion Forward Tube Extrusion

3/23/2020 ME 303 - Section 03b 4

 Transverse/Lateral Extrusion

3/23/2020 ME 303 - Section 03b 5

 Classification of Drawing
DRAWING
DRAWING

Drawing of tubes Drawing of wires, rods and slabs

Drawing of tubes Drawing of wires, rods and slabs

Drawing of tubes without a mandrel

Drawing of tubes without a mandrel

Drawing of tubes with a stationary mandrel

Drawing of tubes with a stationary mandrel

Drawing of tubes with a free mandrel

Drawing of tubes with a free mandrel

Drawing of tubes with a moving mandrel

Drawing of tubes with a moving mandrel

Ironing
Ironing

3/23/2020 ME 303 - Section 03b 6

 Drawing
Wire Drawing Tube Drawing

3/23/2020 ME 303 - Section 03b 7

 Forward Rod Extrusion Force by the
Elementary Theory of Plasticity

The total external work for deformation composes as:

Wtotal  Wideal  W friction  Wshear  WBending

For quasi-stationary processes the total forming force is:

Wtot
Ftot 
punch displaceme nt

yielding: Ftotal  Fideal  F friction  Fshear  FBending

3/23/2020 ME 303 - Section 03b 8

 Forward Rod Extrusion – Ideal Work
Ideal work:

dWideal  z  2r   dr   r  A  d z    z

 z  dA   r  A  d z    z
Using volume constancy V  A  z  constant

dA
we obtain dWideal  V    r   z 
A
The infinitesimal dWideal dA
specific ideal work: dwideal     r   z 
V A

3/23/2020 ME 303 - Section 03b 9

 Specific Ideal Work

Using the Tresca yield criterion z r   f

dA
leads to dwideal   f 
A A1
dA
Integrating over the deformation zone: wideal   dwideal     f 
A0
A
A1
dA  A0 
Utilizing the mean value theorem: wideal   fm    fm  ln 
A0
A  A1 
1
1  f 0   f1
The mean flow stress is defined as:  fm  
  0
 f (  )  d 
2
3/23/2020 ME 303 - Section 03b 10
 Total Ideal Work
The work to deform a material of volume V is simply:

A 
Wideal  wideal  V  V   fm  ln  0 
 A1 

The ideal equivalent strain for  A0 

extrusion (drawing) is defined as:  eq  ln 
 A1 

Finally, we obtain: Wideal  V   fm   eq

3/23/2020 ME 303 - Section 03b 11

 Assumptions on Pressures
 It is difficult to determine local stresses in the
scope of the elementary theory of plasticity.
 Pressure distributions in the container and
die-shoulder must be assumed.
 Siebel assumes that the internal pressures
are in the order of the local yield stresses:
 Interface pressure in container ~ f0 (Y0)
 Interface pressure at die-exit ~ f1 (Y1)
 Interface pressure in shoulder ~ fm (Ym)

3/23/2020 ME 303 - Section 03b 12

 Frictional Work for Die Shoulder
Frictional Work:
die  shoulder
W friction  W friction
container
 W friction

  d  s dz
die  shoulder
dW friction     fm  
cos  cos 

The decrease in the cross-sectional area is:

  d  dz  tan    dA
V
Also: s 
A

3/23/2020 ME 303 - Section 03b 13

 Frictional Work (Cont’d)

Hence: V 1
die  shoulder
dW friction      fm   dA 
A cos   sin 

Integrating between A0 A0 
W die  shoulder
 V   fm  ln 
A1 cos   sin 
friction
and A1 results:

Utilizing the concept of 2

die  shoulder
W friction  V   fm   eq 
the equivalent strain: sin 2

3/23/2020 ME 303 - Section 03b 14

 Frictional Work for Container
r container
dW friction    d 0  h      f 0  ds
z
Utilizing the relationship
Y0
dz
initial
position
Y0 s  h0  h
ds
final
position and integrating between h0 and h
d0
yields

   d 0     f 0  h02  h 2 
container 1
W friction
2

3/23/2020 ME 303 - Section 03b 15

 Forward Rod Extrusion – Shearing
Work
1
r Infinitesimal shearing dWshear 0   f 0  tan   dV
work at inlet: 2
z r0
Integrating over the whole inlet shear zone:
r dr r0
1 r 1
Wshear 0    f 0   2r  s  dr    s   f 0  r03 / s
0
2 s 3

dV Specific shearing
s work at inlet: Wshear 0 1
wshear 0     f 0  tan 
max0
V 3
max1 Specific shearing
1
work at outlet: wshear1    f 1  tan 
2 3
Total shearing work 2
for a volume V: Wshear   V   fm  tan 
3
3/23/2020 ME 303 - Section 03b 16
 Shearing Work (Cont’d)
r0

r s tan Wshear 0   (s  tan  ) max 0 (2r  dr )

0
max0
dA r0
s r 1
Wshear 0   (s  )  f 0  2r  dr
0
s 2
s 1
   s   f 0  r03 / s
3
V r0
s  , tan   , A  r02 
A s
1 V 1
Wshear 0   f 0 ( r0 ) 
2
 tan    f 0 V tan 
3 A 3

3/23/2020 ME 303 - Section 03b 17

 Forward Rod Extrusion Force
The total forming work required for a volume of V by Siebel (1925):

2 2   1

Wtotal  V   fm    tan   1   eq      d 0     f 0  h0  h
  2 2
 
3  sin 2   2

2  2   and
Container
F friction    d 0  h    Y0
with F  A0  Ym    tan   1   
 eq 
 3  sin 2  
The total average forming force can be determined as Siebel (1925):

2  2  
F F F container
 A0   fm    tan   1     eq     d 0  h     f 0
 sin 2 
friction
3 

3/23/2020 ME 303 - Section 03b 18

 Example - Extrusion

Example 1:
A 110Ø75 mm billet made of C15 steel
(annealed) is cold extruded to Ø45 mm in a die
with a die angle of 2 = 90o. If the flow curve
of C15 can be represented by
 f  700   eq0.24 MPa
with an initial flow stress of
 f 0  240 MPa
Determine the extrusion force. Assume that the
coefficient of Coulomb friction is 0.06.

3/23/2020 ME 303 - Section 03b 19

 Extrusion Force by Empirical Methods
A0 A 
Extrusion ratio: Re  Equivalent strain:  eq  ln Re  ln 0 
A1  A1 
6  v punch  d 02  tan 
Mean strain rate: m   eq (required in hot extrusion)
d d
3
0
3
1

Extrusion force F  pe  A0  Qe   fm  A0 with Qe  0.8  1.2   eq

(without container friction)

F  F  F0 friction  F    d 0   friction  
container
For forward extrusion:

For backward can extrusion Fpiercing  (3 to 5)   fm  ( A0  A1 )

check also the piercing force:

3/23/2020 ME 303 - Section 03b 20

 Drawing Force by Empirical Methods

d 0  d1
where h
2

A0
Drawing stress at the exit:  z1   fm  1    cot      ln
A1

h h
where   0.88  0.12  (axisymmetrical) or   0.8  0.2  (plane strain)
L L

Drawing force: F   z1  A1
Remark: Centerburst (Chevroning) occurs if h/L  2.

3/23/2020 ME 303 - Section 03b 21

 Example - Drawing

Example 2:
A shaped wire is drawn from annealed,
3-mm-diameter 302 stainless steel wire. d0
The cross-sectional area of the shape is
5.0 mm2. A commercial oil-based
lubricant is used, the dies have 12o
included angle, and drawing speed is 2
m/s. Calculate the force and power
requirements. Take the coefficient of
friction 0.04 and the material constants d1
in the Ludwik expression as
K = 1300 MPa and n = 0.3.
Ftotal
3/23/2020 ME 303 - Section 03b 22
 Backward Can Impact Extrusion Force
The relative area reduction is
defined as

3 3 A0  A1 d i2
A   2
2 1 A0 de

The solution by Dipper (1949) is

valid for:

 A  0.5 to 0.6

3/23/2020 ME 303 - Section 03b 23

 Backward Can Impact Extrusion - Zone 2
1
Upsetting in Zone 2: The effective coefficient of friction:    1  0.5
2
Force equilibrium
in z-direction:
 z 2   z 2  d z 2    d e2  d i2   2     f 2  dz  d i  s  2  
4 2

Simplifying yields:  d z  s  2     f 2  dz

2    f 2  z 2m    f 2 
b
Integrating:  z2    b  z  Mean stress:
s
s

 b
Using Tresca’s yield criterion:  r 2 m   z 2 m   f 2   f 2  1    
 s

3/23/2020 ME 303 - Section 03b 24

 Backward Can Impact Extrusion - Zone 1

Upsetting in Zone 1: Let us consider radial force equilibrium:

 r1   r1  d r1  2    r  b  2  1   f 1  2    r  dr  d 1  b  2  1   f 1  dr
2  1   f 1  d i 
Integration:  r1      r    r 2m
b 2 
1 d
Mean stress:  rm    1   f 1  i   r 2 m
3 b
Applying Tresca’s         1  1    d i     1    b    p
zm rm f1 f1  1  f2   punch
yield criterion:  3 b   s 
 di 
With:  f 1   eq1  ln h0 b   f 2   eq ,total   eq1   eq 2  ln h0 b   1  
   8s 

3/23/2020 ME 303 - Section 03b 25

 Piercing Force by Empirical Methods*
Constrained Piercing: Unconstrained Piercing:
dp dp

d0 d0

Fpunch  3 to 5   fm  Ap Fpunch  3   fm  A p for d 0 d p  3

[*] Adapted from Schey (1987).

Fpunch  d 0 d p   fm  A p for d 0 d p  3

3/23/2020 ME 303 - Section 03b 26

 Example – Backward Impact Extrusion

Example 3:
A C15 steel can of 70 mm outer diameter
and 58 mm inner diameter is to be produced
by the back extrusion of 70-mm diameter
annealed slugs (initial length = 35mm). The
can base is 5 mm thick. If the flow curve of
C15 can be represented by
 f  700   eq0.24 MPa
with an initial flow stress of
 f 0  240 MPa
Determine the extrusion force. Assume that
the coefficient of Coulomb friction is 0.06.

3/23/2020 ME 303 - Section 03b 27

 Summary

3/23/2020 ME 303 - Section 03b 28

 Remarks on Extrusion and
Drawing - Remark 1
 For the reducing type
extrusion (a.k.a. open-
die extrusion) process,
the friction force in the
container must be
omitted since during
reducing there is no
contact between the
billet and the
container.

3/23/2020 ME 303 - Section 03b 29

 Remark 2
 In the case of
backward (impact)
extrusion, the frictional
force in the container
must be omitted.

3/23/2020 ME 303 - Section 03b 30

 Remark 3
 Rod extrusion is usually
performed with a die-angle
of 2=180o.
 A dead zone is built at the
corners of the die leading to
an artifical cone of 2’=90o.
 In that case, the friction
force in the die shoulder
must be taken as Fideal with
  = 0.5
 ’=  = 45o

3/23/2020 ME 303 - Section 03b 31

 Remark 4
 The computations of the
forces for tube drawing
process assume that the
inner diameter of the tubes
do NOT change.
 If the inner diameters
change, bending force
components must be taken
into consideration.
Here, bending force occurs!

3/23/2020 ME 303 - Section 03b 32

 Remark 5
 In case of forward
impact extrusion of
tubes, the interface
friction (pr) at the
mandrel-exit can be
assumed as 10...12
MPa.
 In this region, the
material is not
plastic anymore!

3/23/2020 ME 303 - Section 03b 33

 Remark 6
 The negative sign in the
friction force at the
mandrel-die interface
must be used in the case
of ironing process.
 In that case, the force at
the base of the tube is
obtained.
 To compute the pressing
force (Fp), this frictional
force must be omitted!
3/23/2020 ME 303 - Section 03b 34