METAL FORMING ANG

SHAPING

ASSIGNMENT

SAADAT MALIK

MY-43

T.E

Q#1 WHAT IS FLOW STRESS? HOW FLOW STRESSES CAN BE DETERMINED

AND WHICH TECHNIQUE DO YOU RECOMMEND? JUSTIFY YOUR
RECOMMENDATION ON SOLID REASONS

Flow Stress
Flow stresses occur when a mass of flowing fluid induces a dynamic pressure on a
conduit wall. The force of the fluid striking the wall acts as the load. This type of stress
may be applied in an unsteady fashion when flow rates fluctuate. Water hammer is an
example of a transient flow stress.

DETERMINATION OF FLOW STRESS OF METAL

The yield stress of a metal under uni-axial load conditions, as a function of strain, strain rate and
temperature can also be considered as a flow stress or effective stress. The definition of the effective stress
as a representation of stress, under combined loading.
The flow stress sigma bar is important because in metal forming processes the forming loads and stresses
depend on

1) Part geometry

2) Friction

3) The flow stress of the deforming material.

The flow stress of metal is influenced by:

 Factor unrelated to the deformation process, such as a chemical composition, metallurgical

structure, phase, grain size, segregation and prior strain history
 Factor explicity related to the deformation process, such as temperature, degree of deformation
and rate of deformation. The degree of deformation and the rate of deformation under general
loading are measured by effective strain and the effective strain rate respectively, thus the
flow stress can be expressed as a function of temperature T. strain , strain rate and micro
structure S :

Q#2 EXPLAINS THE EFFECT OF STRAIN AND TEMPERATURE ON FLOW STRESSES.

EFFECT OF STRAIN RATE & TEMPERATURE ON FLOW STRESS
Forming process parameters, such as strain, strain rate and temperature, also play an extremely important
role. Such forming parameters even receive much high attention from metal forming engineers. With the
increased temperature, the material becomes softer, so the flow stress decreases. One exception to this is
the temperature range within which a phase transformation occurs

In this temperature range the flow stress could increase significantly with the increase of temperature.

The influence of strain can be described in a very rough way as, flow stress increase with a increase of
strain. This statement is correct for cold forming .For hot forming, sometimes it is not correct, especially
when the strain is very high. In this case, the flow stress reach a certain peak value, then may decrease or
keep constant with the increase of the strain The influence of strain dependents on two major factors: work
hardening and softening (recovery and recrystallization). During cold rolling, recrystallization does not
occur. Work hardening is a dominant factor. However in the case of hot rolling, recrystallization also play a
very important role. The recrystallization also depends on the strain, strain rate and temperature. So it is a
very complicated process. The peak stress is determined by both the stain and the temperature.

In general, with the increase of strain rate, the flow stress increase
Q#3 DESCRIBES VARIOUS DEFECTS ENCOUNTER IN EXTRUSION. HOW THEY
CAN BE OVERCOME?

Extrusion Defects:
Due to improper material conditions and process variables, several types of defects can
be developed in extruded products. There are three principle extrusion defects:

Surface cracks (also called speed cracks)

Cause: high speed or high speed and friction. These cracks are intergranular (along
the grain boundaries) and are usually caused by hot shortness. Hot shortness is the
tendency for some alloys to separate along grain boundaries when stresses of
deformed at high tem peratures due to the low melting point constituents segregated at
grain boundaries.

Solution: Reduce billet temperature and extrusion speed.

Piping (also called fish tailing)

Cause: Surface oxides and impurities. According to the metal flow pattern, surface
oxides and impurities are drawn towards the center during deformation, as much as one
third of the extruded product length m ay contain this type of defect, and have to be cut
off as scrap.

Solution: Piping can be minimized by modifying the flow pattern and controlling friction,
or by machining the billet outer surface before extrusion to remove surface scales.

Internal cracks

Cause: high internal stresses at the centerline. Internal cracks are due to high internal
stresses near the centerline in the deformation zone of the extrusion die. The tendency
y for center cracking: Increases with the increase of die angle and amount of impurities.

Solution: Select proper die geometry and extrusion variables. Decreases with the
increase of extrusion ratio and friction.

Q#4 EXPLAINS DIFFERENT PROCESSES FOR THE PRODUCTION OF TUBES AND

SEAMLESS PIPES BY EXTRUSION.

Production of Hollow Shapes and Tubes:

Steel pipes are long, hollow tubes that are used for a variety of purposes. They are
produced by two distinct methods which result in either a welded or seamless pipe. In
both methods, raw steel is first cast into a more workable starting form. It is then made
into a pipe by stretching the steel out into a seamless tube or forcing the edges together
and sealing them with a weld. The first methods for producing steel pipe were
introduced in the early 1800s, and they have steadily evolved into the modern
processes we use today. Each year, millions of tons of steel pipe are produced. Its
versatility makes it the most often used product produced by the steel industry.

REFERENCES:

http://en.wikipedia.org/wiki/Flow_stress

http://www.freepatentsonline.com

http://www.diytrade.com

http://www.steellinks.com