Continuous forming (Wire drawing)

Discrete forming process (Forging)

•
Effects of temperature on forming
Both plastic deformation and friction contribute to heat generation
• Approximately 90-95% mechanical energy involve in processing is transformed into heat
• Metal forming both plastic deformation and friction contribute to heat generation
• About 90-95% of mech. energy is involved in the process of deformation is transformed into heat
• High speed forming operation such as drawing, extrusion temperature rise is more significant
• Heat affect the forming as well as equipment
• Continuous forming operations like drawing, extrusion, etc generally perform at high speeds
• Temperature rise in such process is significant in deciding tool life, dies and properties of the finish part
• A part of heat generated remains in the deform metal and another part close into the tooling and little
close in deformed portion of material
• Lubrication reduces the temperature rise and determined the deformation speed
• Temperature generates during plastic deformation greatly influence the productivity of metal forming
process
• Magnitude and distribution of temperature depends on 1. starting material and initial die temperature, 2.
heat generation due to plastic deformation and frictional heat at the die interface, 3. heat transfer
between deforming material of the die and between work material and environment, 4. temperature
gradient between the deforming the material and die
• Temperature variation of discrete parts forming like forging, upsetting, deep drawing and increase in
continuous forming like wire drawing/rod drawing
• Discrete types deformation takes place in short period of time (deforming material is contact with the dies
during short interval) and die cools of then the process repeated
• In continuous forming such as wire drawing metal flow is study and deforming material is continuously in
contact with the die there is a cumulative increase in temperature that significantly affect the die life
production rate , quality of the raw material
• Die contact pressure exist in the interface also play in significant role in temperature rise
 Effects of temperature on forming
• Temperature has significant effect on the metal properties during forming
• The strength of the material is reduced while increasing ductility (plasticity) at
elevated temperature
• Most of metals can be formed easily at elevated temperature than when they are
cold
• Mechanics of deformation is plastic forming is converted into heat
• Heat conversion due to working is not 100% since small portion and heat is
retained with the metal as stored elastic energy. (5-10% in certain alloys)
• For frictionless process, with full conversion into heat due to plastic work, the
temperature rise (ΔT)
ℎ
ΔT = 𝜌𝑐𝑡
ht = specific energy
ρ = density
c = specific heat of metal
(for Al -75oC, Ti = -530oC)
Increasing the temperature usually increase ductility and toughness and
lowers modulus of elasticity, yield stress, ultimate tensile strength
• Lubrication/cooling could reduce the
temperature
• The magnitude of temperature rise depends
on
1. starting material
2. die temperature
3. plastic work heat and frictional heat at
tool-work interface
• Internal shearing during deformation causes distortion of plastic
reaction as they pass through deformation zone
• As a result and product to have greater strain, causing to be harder,
stronger and less ductile
• Heating the material at temperature above ½ the melting
temperature (in kelvin)- hot deformation, several metallurgical
mechanism operate simultaneously.
• strain hardening due to increase in dislocation density
• Sufficient internal energy is available at elevated temperature to
initiate dynamic recovery and recrystallization
• These annihilate dislocation causing softening of material
• These Combined effect lower the stresses needed for deformation
• Softening of material during hot working requires lesser forming
stresses for deformation
- less powerful metal working equipment needed
- tensile and yield strength decreases as temperature is
increased -metal plasticity is greater between recrystallized and
melting temperature
Deformation rate – relative deformation/unit time
• Temperature also affects strain hardening
exponent, and decreases with increase in
temperature
• Depending on material composition,
impurities level, elevated temperature has
significant effect of forming
• Flow stress deformation strain rate and
temperature
σ = c𝜀 ሶ 𝑚
c – strength constant depends on stress
m = strain rate
 Problems areas in angles of metal
forming
• Plastic zone
• Workpiece at initial stage
• Workpiece at fixed stage – finish part
• Interface between workpiece and die
• Dies
• Surface layer of the workpiece and product
• Forming equipment
 𝑒𝑥𝑥 𝑒𝑦𝑥 𝑒𝑧𝑥
𝑒ሶ = 𝑒𝑥𝑦 𝑒𝑦𝑦 𝑒𝑧𝑦
𝑒𝑥𝑧 𝑒𝑦𝑧 𝑒𝑧𝑥

𝜖ሶ ҧ
 Flow stress of metals
• The yield stress of metal under uniaxial condition
as the function of strain, strain rate and
temperature can be considered as a flow
stress/bar stress
Importance of flow stress in forming
• Forming load and stress depends on
(i) part geometry
(ii)friction at the contacting surface
(iii) flow stress on deforming material
Flow stress on deformation material of influence by
Importance of flow stress