Ain Shams University

Faculty of engineering
Design & Production Dep,

Theory of Metal Forming MDP 381

Fall 2023

Lab report (2)

Subject: Upsetting

Student Name: Ahmed Mohamed Ahmed Elshahat Bisar

Student ID : 1900106

Remarks: Degree:
Introduction

Upsetting: It’s a deformation process in which a billet is compressed between two

dies in a press. This operation reduces the height of the round billet and increases its
diameter.

- The objective of the experiment is to investigate some of the main factors

affecting the upsetting process such as: material type, diameter of the
specimen and the friction between the specimen and the die.

The Factors affecting Upsetting required load:

1) Material type: Different materials have varying mechanical properties, such

as yield strength and ductility, which influence how much force is needed to
deform them.
Materials with higher yield strengths will generally require a greater deforming
load to undergo plastic deformation during upsetting. Conversely, more ductile
materials require lower loads.

2) Height and Diameter of the specimen: A larger specimen typically

requires more force to deform.
The aspect ratio of the specimen (the ratio of height to diameter) also plays a
role. In some cases, shorter, thicker specimens may require more force
compared to longer, thinner ones.

3) Friction between the specimen and die: Higher friction between the two
surfaces will lead to an increased required deforming load.
Reduced friction, typically achieved through proper lubrication, can lower the
required load help prevent excessive wear on the die and workpiece and will
reduce barreling effect.
Experiment Procedures:

• 1. Measure the diameter and height of the specimen before

upsetting.
2. Perform the upsetting process to the required height.
3. Take oil pressure from the press oil pressure dial gauge and
calculate the actual deforming force.
4.Measure the diameter and height of the specimen after
upsetting.
5.Calculate the pressure distribution in the case of good lubricant.
6.Calculate the mean pressure in the case of good lubricant.
7. Calculate pressure distribution in the case of sticking.
8.Calculate the mean pressure in the case of sticking.
9.Repeat the upsetting sequence for different specimens for
friction and frictionless cases at the inner surface between the die
and specimen.

• Tools used:

1- Hydraulic Press with a Bourdon tube gauge showing the oil pressure.
 2- Vernier Caliber: to measure specimen’s diameter and height.

1) Equations used:

- 𝐴𝑖 ℎ𝑖 = 𝐴𝑓 ℎ𝑓 (to calculate Df)

𝑃𝑜𝑖𝑙 𝐴𝑝𝑖𝑠𝑡𝑜𝑛
- 𝑃𝑚𝑒𝑎𝑛 𝑎𝑐𝑡𝑢𝑎𝑙 = 𝐴𝑓

𝐴𝑝𝑖𝑠𝑡𝑜𝑛 = 0.0578 𝑚2 , 𝑘 = 2 𝑀𝑃𝑎, 𝜇 = 0.05

• In case of upsetting with lubricant

2𝜇 𝐷𝑖
𝑃𝑑𝑖𝑠𝑡 ( −𝑟)
- =𝑒 ℎ𝑖 2
2𝑘

𝜇𝐷𝑓
2𝑘ℎ𝑓 ℎ𝑓
- 𝑃𝑚𝑒𝑎𝑛 𝑡ℎ𝑒𝑜𝑟𝑖𝑡𝑖𝑐𝑎𝑙 = (𝑒 − 1)
𝜇𝐷𝑓
 • In case of sticking upsetting

𝑃𝑑𝑖𝑠𝑡 1 𝐷
- = 1 + ℎ ( 2𝑖 − 𝑟)
2𝑘 𝑓

𝐷𝑓
- 𝑃𝑚𝑒𝑎𝑛 𝑡ℎ𝑒𝑜𝑟𝑖𝑡𝑖𝑐𝑎𝑙 = 2𝑘 (1 + 4ℎ )
𝑓

Experiment Results:

• Upsetting with a lubricant results’ table:

No. 𝒉𝒊 (𝒎𝒎) 𝑫𝒊 (𝒎𝒎) 𝒉𝒇 (𝒎𝒎) 𝑫𝒇 (𝒎𝒎) 𝑷𝒐𝒊𝒍 (𝒃𝒂𝒓) 𝑷𝒎𝒆𝒂𝒏 𝒂𝒄𝒕𝒖𝒂𝒍 𝑷𝒎𝒆𝒂𝒏 𝒕𝒉
(MPa) (MPa)

1 50.3 33.7 37.9 38.82 9 43.951 4.1

2 37.9 38.82 31.5 42.58 7 28.413 4.138
3 31.5 42.58 28.1 45.08 12 43.456 4.164

• Graphs:
𝒓𝒊
1. ( 𝑷𝒎𝒆𝒂𝒏 − ) curve:
𝒉𝒊
2. ( 𝑷𝒅𝒊𝒔𝒕 − 𝒓 ) curve:
 • Upsetting with sticking results’ table:

No. 𝒉𝒊 (𝒎𝒎) 𝑫𝒊 (𝒎𝒎) 𝒉𝒇 (𝒎𝒎) 𝑫𝒇 (𝒎𝒎) 𝑷𝒐𝒊𝒍 (𝒃𝒂𝒓) 𝑷𝒎𝒆𝒂𝒏 𝒂𝒄𝒕𝒖𝒂𝒍 𝑷𝒎𝒆𝒂𝒏 𝒕𝒉
(MPa) (MPa)

1 50.4 32.85 44.6 34.92 6 13 4.783

2 44.6 34.92 30.1 42.5 10 40.74 5.411
3 30.1 42.5 16 58.29 18 38.98 7.64

𝒓𝒇
1. ( 𝑷𝒎𝒆𝒂𝒏 − ) curve:
𝒉𝒇
2. ( 𝑷𝒅𝒊𝒔𝒕 − 𝒓 ) curve:
Comments on results:

1. Values of 𝑃𝑚𝑒𝑎𝑛,𝑎𝑐𝑡𝑢𝑎𝑙 and 𝑃𝑚𝑒𝑎𝑛,𝑇ℎ𝑒𝑜𝑟𝑖𝑡𝑖𝑐𝑎𝑙 are

significantly different. Knowing that the typical value
for ultimate tensile strength for lead is 17-18 MPa and
its tensile yield strength is 1-2 MPa, then we can deduce
that the problem is in 𝑃𝑚𝑒𝑎𝑛,𝑎𝑐𝑡𝑢𝑎𝑙 values.

2. The reason of this problem is probably due to an error in

the Burdon tube pressure gauge that measures oil
pressure in the hydraulic piston.

3. A second reason is the measuring of 𝐴𝑝𝑖𝑠𝑡𝑜𝑛. The

diameter has been measured in the lab was piston rod
diameter not the one of piston itself, Leads to wrong
value for 𝐴𝑝𝑖𝑠𝑡𝑜𝑛.
Lab’s Progress: