Stress strain behavior of ductile materials

DEFORMING

e p

Elastic-plastic with strain hardening Elastic-perfectly plastic Rigid perfectly plastic Rigid plastic with strain hardening

Topics for todays lecture

Deformation processes
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Process characteristics
Material/continuum changes during processing
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Deforming process characteristics Deforming physics Common deforming processes DFM

Machining Deforming

= Local, concentrated = Over large volume

Force
~ ~

Machining: Stamping:

~10s - 100s of lbs ~10s - 100s of tons

Materials - Virtually all ductile materials Shapes Size - Limited by strain/flow - Limited by force/equipment

Advantages and disadvantages

Advantages
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Important physics
Stress/strain
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Parallel process: rapid bulk formation Overall material properties improved

Affect CQFR Affect deforming force -> equipment & energy requirements

Disadvantages
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Friction
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Cost of equipment and dies Limited flexibility in shapes and sizes (i.e. compared to machining) Accuracy Repeatability

Affect on deforming force -> equipment & energy requirements Why lubrication is needed and can help Friction is not repeatable quality.

Stress strain behavior of ductile materials

Example: 12L14 Steel in Duratec

12L14 Steel True Stress-Strain Behavior 600
Intercept

80
Tangent modulus 0.41 GPa [0.06 Mpsi]

500 Stress, MPa 400 300 200 100

70 60 50 Stress, kpsi

Youngs modulus 190 GPa [27.4 Mpsi]

40 30 20 10

Elastic-plastic with strain hardening Elastic-perfectly plastic Rigid perfectly plastic Rigid plastic with strain hardening

0 0.00

0.01

0.02 0.03 mm /mm Strain,

0.04

0 0.05

Forging force and friction

Axisymmetric upsetting
Fz

Forging force and friction

Purpose
~

Find Fz() Sensitivity

Eqxn: A Equilibrium in r direction dFinner arc dFfriction top & bottom dFhoop dFouter arc

dFr = 0 = r h r d 2 p r d dr 2 h dr

d + ( r + d r ) (r + dr ) h d 2

2R

Assumptions:
~ ~ ~

Tresca flow Constant friction coefficient

d r 2 p 2 z = = dr h h
Eqxn: B - Tresca Yield Criterion

z = Y exp

2 (R r ) h

Plastic deformation

r z = Y

Forging force and friction

Affect of friction on contact pressure

Forging force and friction cont.

Y=75000 psi h = inch

Contact pressure [psi]

0 0 -25000 -50000 -75000 -100000 -125000 -150000 Distance from center line [inches] 0.05 0.1 0.15 0.2 0.25 mu = 0 mu = .1 mu = .2 mu = .5 0.3

R 1 h 2 R 2 R Fz = z 2 r dr = ( R 2 ) Y exp 1 0 2 R h h

Now use Taylors series expansion (3 terms) to approximate the exponential function Expand about 0, makes this approximation valid for small values of 2R/h Increasing

2 R Fz = ( R 2 ) Y 1 + 3 h

Forging force and friction

Affect of part size and friction on forging force 10 mu = 0 mu = .1 mu = .2 mu = .5

Common processes
Y=75000 psi h = inch

Sheet metal

Forging force [tons]

Forging

Increasing
2

Extrusion

0 0 0.05 0.1 0.15 0.2 0.25 Part size [inches]

Rolling

Bending and shearing

Forging

Rolling and extrusion

Affect of grain size

Properties affected by grain size
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Strength Hardness Ductility For example (Ferrite)

y = o +

ky d grain

We desire smaller grains for better properties

Recrystallization

DFM for deforming processes

Parting line and flash

Draft angle

Radii

Lubrication

http://www.mmat.ubc.ca/other/courses/apsc278/lecture11.pdf

Mechanics of spring back

Q: Why do we see spring back? A: Elastic recover of material

Example: Elastic spring back

Example: Bending wire

Ro

SB

Ro < R1

1 1 > Ro R1

R1

Quantifying elastic spring back

Elastic recovery of material leads to spring back
~ ~ ~

Y = Yield stress
Ri R Y R Y = 4 i 3 i +1 Rf t E t E
3

E = Youngs Modulus
2

t = thickness
3

1 1 3 Y 4 Ri Y = 3 Ri R f t E t E

With increase in Ri / t or Y

OR

decrease in E spring back increases

Titanium
ing

c In re as
Y/E

Rf

Steel

Ri