metal forming lecture slides

© All Rights Reserved

3 views

metal forming lecture slides

© All Rights Reserved

- General Design Method for Bolted Connections - Soeren Stephan et al
- Geotech Chapter 10 Stress Distribution - Question
- A638A638M-10 Standard Specification for Precipitation Hardening Iron Base Superalloy Bars, Forgings, And Forging Stock for High-Temperature Service
- Torsion Lab report
- 1920 reportonmaterial00jenkrich
- failure theory
- Forging
- Failure Theories
- SS316
- Design Course Material
- Chaboche_Bauchinger
- Karla Overseas Pvt
- FEA of Adhesive Joints
- Strength Caracteristics of Composites Materials
- Forging
- Forging __ KEY to METALS Article
- Forging Book1
- IJETR022214
- Design of Forming Processes Bulk Forming.pdf
- Aluminium.pdf

You are on page 1of 31

(MF F313)

BITS Pilani

Pilani Campus

K S SANGWAN|L5|August 20

Outline

Forging analysis

Types of forgings

Strip Forging

Assumption

forging forcef attains its maximum value at the end of the

operation

is constant

variation of stress field along y-axis is negligible

plane strain case

entire w/p is plastic in state during the process

width is 2l

Consider an element of width dx at a distance x from

origin.

Consider the equilibrium of the element in xdirection.

h d x 2 dx 0..........

......(1)

[ now letx and p are principal stresses

it being a case of plane area

2 ( 1 p ) / 2

applyVON MISES criteria,

p x 2k ]

dp d x ..........

....(2)

puting in (1)

h dp 2 dr 0

dp ( 2 / h ) dx..........

........(3)

BITS Pilani, Pilani Campus

the friction stress are increasing and when

(say) it reaches a value equal to shear yield

stress and it remains constant then after. In

other words from

x 0 to x xs , we have a sliding / non sticking zone

x xs to x l , we have a sticking zone

again u sin g equ(3)

dp 2 / hdx

[ we havex x s , p s k ]

equ(3)becomes

dp (2 p / h )dx

dp / p 2 x / h c1

p (2k / h ) x c2. ...............(5)

to find c1

c1 ln 2k

p ps

p s ( 2k / h) x s c 2

c 2 p s ( 2k / h) x s

ln( p / 2k ) 2 x / h

or p / 2k e 2 x / h

p1 2ke 2 x / h ..........(4)

x xs ,

0 xl

c2 2k[e 2 xs / h x s / h]

p 2k[e 2 xs / h ( x xs ) / h].........(6)

BITS Pilani, Pilani Campus

TO FIND

dx xs ,

ps k ps k /

puting this in equ(4), weget

ps k / 2ke[ 2 xs / h ]

1 / 2 e 2 xs / h

or 2 xs / h ln(1 / 2 )

xs h / 2 ln(1 / 2 )

puting xs in equ(6), we get

p 2k[e ( 2 / h )(h / 2 ) ln(1/ 2 ) 1 / h{x h / 2 ln(1 / 2 )}]

2k[1 / 2 1 / h{x h / 2 ln(1 / 2 )}]

p2 2k[1 / 2 {1 ln(1 / 2 ) x / h}]............(7)

xs x l

BITS Pilani, Pilani Campus

f 2[ p1dx p 2dx]

xs

xs

DISC FORGING

figure, thickness and force at the end of the operation

are h and F respectively:

Consider an elemental disc subtending an angle d at the

centre, between radii r and r + dr.

Considering the radial equilibrium of strip,

( r d r )(r dr)d .h r rd .h 2 dr.h sin d / 2 2 .rddr 0

Now neglecting the higher order term

r rd .h d r rd .h r rd .h 2rddr 0

d r .h 2dr 0 ______________________________________(1)

Let , r , and p are Pr incipal Stresses

Therefore , Putting these values in eq n

( 1 2 ) 2 ( 2 3 ) 2 ( 3 1 ) 2 6k 2

We get

r p 3k ________________________________________(2)

or

d r dp

Put in eq n (1)

hdp 2dr 0 ________________________________________(3)

i.e.

rs r R _______sliding zone

0 r rs _______sticking zone

BITS Pilani, Pilani Campus

p

n

Put in eq (3)

hdp 2pdr 0

dp / p (2 / h)dr

Integrating ,

ln p (2 / h)r C1

BITS Pilani, Pilani Campus

To f ind C1

r R, r 0,

Theref ore f rom eq n ( 2)

p

3k

ln( 3k ) ( 2 / h) R C1

or C1 /( 3k ) e ( 2 / h ) R

or C1

3k e ( 2 / h ) R

Hence, ln p ( 2 / h) r ln

or

p sl

3k e ( 2 / h ) R

3k e ( 2 / h ) R . e ( 2 / h ) r

rs r R

BITS Pilani, Pilani Campus

At r rs , k ,

also p s

Putting, k in eq n (3)

hdp 2kdr 0

or dp (2k / h)dr

Integrating ,

To Find C2 :

At r rs ,

p ps

Putting in eq n (5),

p s (2k / h)rs C2

or C2 p s (2k / h)rs

From eq n (4), by putting r rs and put the value in aboveeq n

C 2 3k e ( 2 / h )(R rs ) (2k / h)rs

Putting C 2 in eq n (5), we get

p (2k / h)r (2k / h)rs 3k e ( 2 / h )(R rs )

p (2k / h)(rs r ) 3k e ( 2 / h )(R rs ) _______________________(6)

BITS Pilani, Pilani Campus

To Find rs :

At r rs , k p s

or

ps k /

k/

3k e ( 2 / h )(R rs )

e ( 2 / h )(R rs ) 1 / 3

(2 / h)( R rs ) ln(1 / 3 )

R rs ( h / 2 ) ln(1 / 3 )

rs R (h / 2 ) ln(1 / 3 )

Putting , rs value in eq n (6)

BITS Pilani, Pilani Campus

(2k / h)R (h / 2 ) ln(1 /

3 ) r

3k e ln(1 /

3 )

3 )

(2k / h)(R r ) (k / ) ln(1 / 3 ) k /

p2

3 ) ______________(7) , (0 r rs )

rs

rs

F p 2 .2r.dr p1 .2r.dr

R

rs

2 p 2 .r.dr p1 .r.dr

0

rs

rs

rs

( 2 / h )( R r )

2 (2k / h)( R r )r.dr 2 (k / ) 1 ln( 3 ) r.dr 2 3ke

.r.dr

rs

2 (2k / h) ( Rr 2 / 2) (r 3 / 3)

rs

0

rs

0

R

rs

Types of Forging

Smith forging

Drop forging

Press forging

Upset forging

Swaging

Roll forging

Roll Forging

Die Features

Fillet radius

Draft

Flash gutter

Shrinkage allowance (hot forging)

Forging Defects

Unfilled sections less metal, improper heating,

misplacement of metal

Scale pits scale in die

Mismatched forging misalignment of two halves of die

Barreling low lubrication

Laps thin web

Internal cracks thick web

Forging Defects

(a) Laps formed by web buckling during forging; web thickness should be increased

to avoid this problem.

(b) (b) Internal defects caused by oversized billet; die cavities are filled prematurely,

and the material at the center flows past the filled regions as the dies close.

BITS Pilani, Pilani Campus

Thanks

- General Design Method for Bolted Connections - Soeren Stephan et alUploaded bySoeren Stephan
- Geotech Chapter 10 Stress Distribution - QuestionUploaded bygautam
- A638A638M-10 Standard Specification for Precipitation Hardening Iron Base Superalloy Bars, Forgings, And Forging Stock for High-Temperature ServiceUploaded bytjt4779
- Torsion Lab reportUploaded byArmando Marquez
- 1920 reportonmaterial00jenkrichUploaded byUlf Dunell
- failure theoryUploaded byTeja Dilip
- ForgingUploaded bymarco rousseau
- Failure TheoriesUploaded byMichael 'El Filósofo'
- SS316Uploaded byNirav Patel
- Design Course MaterialUploaded byharish
- Chaboche_BauchingerUploaded byBlaz Zoubek
- Karla Overseas PvtUploaded byJagadish Jaya Ram
- FEA of Adhesive JointsUploaded byviluk
- Strength Caracteristics of Composites MaterialsUploaded byfondexx
- ForgingUploaded byvelavansu
- Forging __ KEY to METALS ArticleUploaded bykumarpankaj030
- Forging Book1Uploaded byEldori1988
- IJETR022214Uploaded byerpublication
- Design of Forming Processes Bulk Forming.pdfUploaded byAsia Ct
- Aluminium.pdfUploaded byDeepak
- Forging and ForgeabilityUploaded byjestin
- ADA307777.pdfUploaded byPierluigi Romano
- 6_1Uploaded byfirdauz 97
- CivilUploaded byPeter D.
- grilo2018Uploaded byIbrahim Talaat
- A model for swelling rock in tunnelling.pdfUploaded byAgustín Ramos López
- 12785961Uploaded byMichael Altamirano
- 16-ChSoil Model - FLACUploaded byKTMO
- Torsion testUploaded byNidhin K
- Lecture 3__Limit State Design (1).pdfUploaded byKrunal

- cremonaUploaded byUlises Sarayasi
- MF F313 2014 L16Uploaded byaviruddhjain
- MF F313 2014 L15Uploaded byaviruddhjain
- MF F313 2014 L13Uploaded byaviruddhjain
- MF F313 2014 L12Uploaded byaviruddhjain
- MF F313 2014 L3 & L4Uploaded byaviruddhjain
- MF F313 2014 L1Uploaded byaviruddhjain
- ReportUploaded byaviruddhjain
- Design of Jig for Cylindrical DrillingUploaded byaviruddhjain
- GUI BasicsUploaded byaviruddhjain
- SPSS TutorialUploaded byJJ Sumaylo
- Model Solution-Project.pdfUploaded byaviruddhjain
- PS I RegistrationUploaded byaviruddhjain

- A Systematic Study on Wetting Properties of Solids With Differnrent Chemistry and Roughness (Autosaved)Uploaded bysharon
- IACS M53 - Calculation of Crankshafts for I.C EnginesUploaded bybogodavid
- Model Exam1Uploaded byMaha Lakshmi
- Estimation of the Hydrodynamics Coefficients of an ROV using Free Decay Pendulum MotionUploaded byMichael Mays
- Application of the Single Hardening Model in the Finite Element Program ABAQUSUploaded byBogdan Bungardi
- Drop Breakup in Three-dimensional Viscous FlowsUploaded byAmir Abbaszadeh
- example-1Uploaded byTsihatesfa
- CFD Assignment May 2016Uploaded byKelvin Ting S B
- Artigo Erros Relevantes Ensaios Tensao MetaisUploaded bybiancogallazzi
- 1706131 (2)Uploaded byRoland Pongrácz
- Tutorial 6 Solutions Kinematics of Particles.pdfUploaded byBharat Sai
- MAGNETISM.docxUploaded byChandu
- 11 SatUploaded byGhazi Dally
- Structural Analysis ErrataUploaded by陳宣芳
- Box Culvert Design Calculation 12 08 2016Uploaded bycoreteam
- Methods to Reduce Oblique Bending in a Steel Sheet Pile WallUploaded byjawhockx
- Applying Fully Coupled Geomechanics and Fluid Flow Model TheoryUploaded byPeng Ter
- Dynamic Analysis of a Clamped BeamUploaded byFrancisco Lopez Santos
- Electromagnetic WavesUploaded byAaditya Divyam
- Design for Precision Current Status and TrendsUploaded byjavier2299
- hydraulic modeling of torque convertersUploaded byserf007
- report_453.pdfUploaded byjoaosevan
- Multiple Choice 0Uploaded byDave Resurreccion
- Mechanical RepoUploaded byParvin Surwade
- PPTUploaded byhngfhgf
- Satcom 2Uploaded bySameer Mandaogade
- LAS Robert TurbulenceUploaded byJulio Aquije
- Beam Stiff Ness Calculation @BUploaded bytesfu
- Finite Element Analysis of a Cantilever Beam in BendingUploaded byAmir Aziz
- Gyroscopic CoupleUploaded byultimate_gamerzz

## Much more than documents.

Discover everything Scribd has to offer, including books and audiobooks from major publishers.

Cancel anytime.