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Fundamentals of Metal Forming PDF
Fundamentals of Metal Forming PDF
Fundamentals of Metal Forming PDF
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Metal Forming
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Stresses in Metal Forming
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Material Properties in Metal Forming
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Bulk Deformation Processes
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Figure 18.2 – Basic bulk deformation processes: (a) rolling
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Figure 18.2 – Basic bulk deformation processes: (b) forging
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Figure 18.2 – Basic bulk deformation processes: (c) extrusion
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Figure 18.2 – Basic bulk deformation processes: (d) drawing
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Sheet Metalworking
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Figure 18.3 - Basic sheet metalworking operations: (a) bending
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Figure 18.3 - Basic sheet metalworking operations: (b) drawing
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Figure 18.3 - Basic sheet metalworking operations: (c) shearing
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Material Behavior in Metal Forming
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Flow Stress
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Average Flow Stress
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Temperature in Metal Forming
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Temperature in Metal Forming
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Cold Working
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Advantages of Cold Forming vs.
Hot Working
• Better accuracy, closer tolerances
• Better surface finish
• Strain hardening increases strength and hardness
• Grain flow during deformation can cause desirable
directional properties in product
• No heating of work required
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Disadvantages of Cold Forming
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Warm Working
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Advantages of Warm Working
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Hot Working
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Why Hot Working?
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Advantages of Hot Working vs. Cold Working
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Disadvantages of Hot Working
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Strain Rate Sensitivity
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
What is Strain Rate?
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Evaluation of Strain Rate
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Effect of Strain Rate on Flow Stress
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Figure 18.5 - (a) Effect of strain rate on flow stress at an
elevated work temperature. (b) Same relationship
plotted on log-log coordinates
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Strain Rate Sensitivity Equation
Yf C m
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Figure 18.6 - Effect of
temperature on flow stress
for a typical metal. The
constant C in Eq. (18.4),
indicated by the intersection
of each plot with the vertical
dashed line at strain rate =
1.0, decreases, and m
(slope of each plot)
increases with increasing
temperature
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Observations about Strain Rate
Sensitivity
• Increasing temperature decreases C, increases m
At room temperature, effect of strain rate is almost
negligible
Flow curve is a good representation of material
behavior
As temperature increases, strain rate becomes
increasingly important in determining flow stress
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Friction in Metal Forming
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Lubrication in Metal Forming
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”
Considerations in Choosing a Lubricant
©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern Manufacturing 2/e”