Analysis of Metal Forming

Processes
Analysis of Metal Forming Processes

Books:

1. Groover, M.P., “Fundamentals of Modern Manufacturing”, Wiley-

India, 2010.
2. Serope Kalpakjian and Steven R. Schmid, “Manufacturing
Engineering and Technology", Prentice Hall
Material Behaviour in Metal Forming

⚫ Plastic region of stress-strain curve is primary interest

because material is plastically deformed
⚫ In plastic region, metal's behavior is expressed by the
flow curve:

 = K n

where K = strength coefficient; and n = strain

hardening exponent
Flow curve based on true stress and true strain
Flow stress is function of …

⚫ Strain hardening exponent, n

⚫ Strat rate sensitivity exponent, m
⚫ Temperature

⚫ Flow stress equation is also known as …

Flow Stress

⚫ For most metals at room temperature,

strength increases when deformed due
to strain hardening
⚫ Flow stress = instantaneous value of
stress required to continue deforming the
material
Yf = K  n

where Yf = flow stress, that is, the yield

strength as a function of strain
Average Flow Stress
Determined by integrating the flow
curve equation between zero and the
final strain value defining the range of
interest

Yf = K  n

K n
Yf =
1+ n
where Y f = average flow stress; and  =
maximum strain during deformation process
Analysis of Forging
Open die forging of cylindrical w/p – Difference
between top and bottom figures

⚫ upsetting
or upset
forging

(1) start of process with

w/p at its original
length and diameter,
(2) Partial compression,
and
(3) Final size.
Homogeneous deformation (Ideal
condition)
ℎ𝑜
⚫ True strain  = ln( )
ℎ𝑓
⚫ Volume of material will remain constant
𝜋 𝜋
⚫ 𝑉= 𝑑𝑜2ℎ𝑜 = 𝑑𝑓2ℎ𝑓
4 4
⚫ Percentage change in diameter can be calculated as
𝑑𝑓 −𝑑𝑜
⚫ ∗ 100%
𝑑𝑜
⚫ Force F = 𝑌𝑓𝐴𝑓 (where 𝑌𝑓 is flow stress corresponding
to strain)
⚫ Work done (WD) = F ℎ𝑜 − ℎ𝑓 = 𝑚𝑔𝐻
⚫ Change in length because of forging
𝐿𝑓
⚫ True strain  = ln( )
𝐿𝑜
Inhomogeneous deformation
(Real condition)
⚫ Force F = 𝐾𝑓𝑌𝑓𝐴𝑓, where Kf is a factor
𝐷𝑓
⚫ 𝐾𝑓 = (1 + 0.4 )
ℎ𝑓
Example 1
A cylindrical part is upset forged in an open die. The
initial diameter is 45 mm and the initial height is 40 mm.
The height after forging is 25 mm. The coefficient of
friction at the die-work interface is 0.20. The yield
strength of the work material is 285 MPa, and its flow
curve is defined by a strength coefficient (K) of 600 MPa
and a strain-hardening exponent of 0.12. Determine the
force in the operation (a) just as the yield point is
reached (yield at strain = 0.002), (b) at a height of 35
mm, (c) at a height of 30 mm, and (d) at a height of 25
mm.
Solution:
(a)
V =  𝐷2𝐿/4 =  (45)2(40)/4 = 63617.25 mm3
Given:  = 0.002, and K = 600
Yf = 600(0.002)0.12 = 284.6 Mpa and
h = 40 – 40*0.002 = 39.92
Af = V/h = 63617.25/39.92 = 1593.62 mm2
Find Df from Af = 1593.62 =  𝐷𝑓2/4 . Thus, Df = 45.05 mm
Kf = 1 + 0.4(0.2)(45.05)/39.92 = 1.09
F = Kf*Yf*Af = 1.09*284.6*1594 = 494481.1 N
(b)
Given h = 35 mm and  = ln(40/35) = 0.1335
Yf = 600*(0.2335)0.12 = 471.2 MPa
V = 63617.25 mm3, calculated earlier in (a)
At h = 35, Af = V/h = 63617.25/35 = 1817.64 mm2
Df = sqrt(1817.64*4/  ) = 48.11 mm
Kf = 1 + 0.4(0.2)(48.11)/35 = 1.11
F = Kf*Yf*Af =1.11*471.2*1818 = 950872.2 N
(c)
(d)
Assignment
A cylindrical part is upset forged in an open die. The
starting diameter 50 mm and height 40 mm. Height after
forging 30 mm. Coefficient of friction at the die-work
interface 0.20. Yield strength of the low-carbon steel
105 MPa, and its flow curve is defined by a strength
coefficient 500 MPa and a strain hardening exponent
0.25 Determine the force in the operation (a) just as the
yield point is reached (yield at strain = 0.002), (b) at a
height of 35 mm, and (c) at a height of 30 mm.
Assignment
A cold heading operation is performed to produce the
head on a steel nail. The strength coefficient (K) for this
steel is 600 MPa, and the strain hardening exponent is
0.22. Coefficient of friction at the die-work interface is
0.14. The wire stock out of which the nail is made is 5
mm in diameter. The head is to have a diameter of 9.5
mm and a thickness of 1.6 mm. The final length of the
nail is 120 mm. Determine: (a) What length of stock must
project out of the die in order to provide sufficient volume
of material for this upsetting operation? (b) Compute the
maximum force that the punch must apply to form the
head in this open-die operation.
Solution

⚫ There is mistake Do = 5 mm. Ao = 19.63

mm2, ho= 5.78, strain = 1.284, Yf =
633.92
Assignment
A hot upset forging operation is performed in an open
die. The initial size of the workpiece is: Do = 25 mm, and
ho = 50 mm. The part is upset to a diameter = 50 mm.
The work metal at this elevated temperature yields at 85
MPa (n = 0). Coefficient of friction at the die-work
interface = 0.40. Determine (a) final height of the part,
and (b) maximum force in the operation.
Solution
Assignment
A hydraulic forging press is capable of exerting a
maximum force = 10,00,000 N. A cylindrical workpiece is
to be cold upset forged. The starting part has diameter =
30 mm and height = 30 mm. The flow curve of the metal
is defined by K = 400 MPa and n = 0.2. The coefficient of
friction = 0.1. Can forging press compress final height of
10 mm?
Solution
Forging of Strip

Book:

Ghosh A. and Mallik A. K., “Manufacturing

Science” East West Press New Delhi,
2008.
Forging of Strip

⚫ Objective: To determine forging force

1. The forging force, F, attains its maximum value at the end of the
operation.
2. The co-efficient of friction, , between the workpiece and the dies
(plates) is constant.
3. The thickness of w/p is small as compared with its other dimensions
and the variation of the stress field along the y-direction is
negligible.
4. The length of the strip is much more than the width and hence, the
problem is the plain strain type.
5. The entire w/p is in the plastic state during the process.
Details of forging operation

Details of forging operation Stresses on element

• At the given instant shown in above Figure (left), the thickness of

the w/p is h and the width is 2l.
• In the Figure (right), an element of width dx at a distance x from the
origin is shown with all the stresses acting on it.
• In the analysis, the length of the w/p, i.e., in z-direction, is
considered as unity.
Or
or
+
 and along with the expression of ps

or

or
Numerical Problem

To find total forging force, the value of xs is required (Eq. 8).

The force per unit length, F, is calculated as
Assignment

⚫ Solve the above example when the

coefficient of friction is 0.08.

⚫ Ans. Forging force, F = 0.238 x 106 N

Thank you