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Fum and A Mentals of Metal Forming
Fum and A Mentals of Metal Forming
Solution:
The draft attempted in this rolling operation is
d = 25 – 22 = 3 mm
From Eq. (1), the maximum possible draft for the given coefficient of
friction is
Since the maximum allowable draft exceeds the attempted reduction, the
rolling operation is feasible. To compute rolling force, we need the contact
length L and the average flow stress Yf The contact length is given by Eq,
(2):
250 25 22 27.4 mm
25
0.128
22
.
275 0.128
175.7 MPa
1.15
F = 175.7(300)(27.4) = 1,444,786 N
For comparison, let us convert this to horsepower (we note that one
horsepower = 745.7 W):
207,201
278hp
745.7
It can be seen from this example that large forces and power are required
in rolling. Inspection of Eqs. (3) and (5) indicates that force and/or power
to roll a strip of a given width and work material can be reduced by any of
the following: (1) using hot rolling rather than cold rolling to reduce
strength and strain hardening (K and n) of the work material; (2) reducing
the draft in each pass; (3) using a smaller roll radius R to reduce force; and
(4) using a lower rolling speed N to reduce power.
Example: 2
Solution:
Work piece volume V = 75π (502/4) = 147,262 mm2. At the moment
contact is made by the upper die, h = 75 mm and the force F = 0. At the
start of yielding, h is slightly less than 75 mm, and we assume that strain =
0.002, at which the flow stress is
0.4(0.1)(50)
K f = 1+ = 1 .027
75
75
∈= In = I n(1.21) = 0.1904
62
Y f = 350(0.1904).17 = 264.0MPa
Wire is drawn through a draw die with entrance angle = 15o. Starting
diameter is 2.5 mm and final diameter = 2.0 mm. The coefficient of
friction at the work-die interface = 0.07. The metal has a strength
coefficient K = 205 MPa and a strain hardening exponent n = 0.20.
Determine the draw stress and draw force in this operation.
Solution:
The values of D and L, for Eq. (6) can be determined using Eqs. 19.34. D
= 2.25 mm and L, = 1.0 mm. Thus,
2.25
0.88 0.12 1.15
1.0
The areas before and after drawing are computed as Ao = 4.91 mm2 and Af
= 3.14 mm2. The resulting true strain = In (4.91/3.14)= 0.446. And the
average flow stress in the operation is computed:
.
205 0.446
145.4MPa
1.20
.
145.4 1 1.15 0.446 94.1 MPa
Finally, the draw force is this stress multiplied by the cross-sectional area
of the exiting wire:
F = 94.1(3.14) = 295.5 N.
Maximum Reduction per Pass A question that may occur to the reader
is: Why is more than one step required to achieve the desired reduction in
wire drawing? Why not take the entire reduction in a single pass through
one die, as in extrusion? The answer can be explained as follows. From
the preceding equations, it is clear that as the reduction increases, draw
stress increases. If the reduction is large enough, draw stress will exceed
the yield strength of the exiting metal. When that happens, the drawn wire
will simply elongate instead of new material being squeezed through the
die opening. For wire drawing to be successful, maximum draw stress
must be less than the yield strength of the exiting metal.
It is a straightforward matter to determine this maximum draw stress
and the resulting maximum possible reduction that can be made in one
pass, under certain assumptions.
Let us assume a perfectly plastic metal (n = 0), no friction, and no
redundant work. In this ideal case, the maximum possible draw stress is
equal to the yield strength of the work material. Expressing this using the
equation for draw stress under conditions of ideal deformation, Eq. (8),
and setting Yf = Y (because n = 0),
1
1
1.0 (9)
2.7183 (10)
0.632 (11)
The value given by Eq. (11) is often used as the theoretical maximum
reduction possible in a single draw, even though it ignores the effects of
friction and redundant work, which would reduce the' maximum possible
value, and strain hardening, which would increase the maximum possible
reduction because the exiting wire would be stronger than the starting
metal. In practice, draw reductions per pass are quite below the theoretical
limit. Reductions of 0.50 for single-draft bar drawing and 0.30 for
multiple-draft wire drawing seem to be the upper limits in industrial
operations.
Example 4
Solution:
(a) The clearance allowance for half-hard cold-rolled steel is a = 0.075.
Accordingly,
The blank is to have a diameter = 150 mm, and die size determines blank
size. Therefore,
(b) To determine the blanking force, we assume that the entire perimeter
of the part is blanked at one time. The length of the cut edge is
150 471.2 mm