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Plastic Deformation, Flow Stress and Formability
Plastic Deformation, Flow Stress and Formability
Plastic Deformation, Flow Stress and Formability
Plastic
deformatio
n
Point and
line Defects
Slip and
Twinning
Systems
Flow
stress
Formability
When a sufficient
load is applied to a
metal or other
structural material, it
will cause the
material to change
shape. This change
in shape is called
deformation. When a
material is deformed,
two types of
deformation occur:
elastic and plastic.
Plastic deformation
When the stress is sufficient to
permanently deform the
metal, it is called plastic
deformation. As discussed in
the section on crystal defects,
plastic deformation involves
the breaking of a limited
number of atomic bonds by
the movement of dislocations.
Elastic deformation
The elastic phase is the initial
phase, in which the material
will change shape as load is
applied. However, when the
load is removed, the material
returns to its original shapes.
This type of deformation
involves stretching of the
bonds, but the atoms do not
POINT DEFECTS
A vacancy exists when an atom is missing from a
normal lattice position.
Higher than equilibrium concentrations of
vacancies can also be produced by extensive
plastic deformation (cold work).
An atom that is trapped inside the crystal at a
point intermediate between normal lattice
position. The interstitial defect occurs in pure
metals as a result of bombardment with highenergy nuclear particles, but is does not occur
frequently as a result of thermal activation.
The presence of an impurity atom at a lattice
position or at an interstitial position results in a
local disturbance of the periodicity of the lattice,
the same as for vacancies and interstitials.
Line Defects
Line defects or dislocations are important for plastic deformations. The following two types of dislocations are observed:
Edge
dislocations
Screw
dislocations
DISLOCATIONS
IN AN EDGE DISLOCATION, LOCALIZED LATTICE DISTORTION
EXISTS ALONG THE END OF AN EXTRA HALF-PLANE OF ATOMS.
A SCREW DISLOCATION RESULTS FROM SHEAR DISTORTION.
MANY DISLOCATIONS IN CRYSTALLINE MATERIALS HAVE BOTH
EDGE AND SCREWS COMPONENTS; THESE ARE MIXED
DISLOCATIONS.
PLASTIC DEFORMATION CREATES A LARGE NUMBER OF
DISLOCATIONS. HIGHER THE DISLOCATION DENSITY IN THE
MATERIAL, HIGHER IS THE RESISTANCE TO MOVEMENT OF
DISLOCATIONS AND HENCE HIGHER FORCES ARE REQUIRED
FOR PLASTIC DEFORMATION. THIS EXPLAINS THE INCREASE IN
STRENGTH DURING PLASTIC DEFORMATION, WHICH IS CALLED
STRAIN HARDENING OR WORK HARDENING.
DEFORMATION BY SLIP
The usual method of plastic
deformation in metals is by
the sliding of blocks of the
crystal over one another
along definite
crystallographic planes,
called slip planes.
Slip occurs when the shear
stress exceeds a critical
value. The atoms move an
integral number of atomic
distances along the slip
plane, and a step is
produced in the polished
surface.
SLIP
SLIP SYSTEMS
DEFORMATION BY TWINNING
DEFORMATION BY TWINNING
Twins can form in a time as short as a few microseconds,
while for slip there is a delay time of several milliseconds before
a slip band is formed. Under certain conditions, twins can be heard
to
form with a click or loud report (tin cry) . If twinning occurs during
a
tensile test, it produces serrations in the the stress-strain curve.
The important
role of twinning in plastic deformation comes not from the strain
produced
by the twinning process but from the fact that orientation changes
resulting from twinning may place new slip systems in a favorable
orientation
with respect to the stress axis so that additional slip can take
DISLOCATION MOTION IN
POLYCRYSTALS
FLOW STRES
In metal forming processes, the forming loads and material
stresses depend on the part geometry, fiction, and flow stress of
the metal being formed. When the applied stress, in uniaxial
tension, without necking, reaches the yield stress (flow stress), the
material in considered to Begin deforming plastically. Flow stress
is simply the yield stress of a material undergoing unixial
deformation, as a function of strain, strain rate, temperature, and
microstructure:
- flow stress
- temperature- efective strain
- effective strain rate
S- microstructure
Where:
average flow stress;
= maximumstrain during deformation process
FORMABILITY
Formability describes the limit to which the sheet
materials can undergo deformation before failure during
forming. Several test have been develop specifically to
evaluate the abilities of a sheet material to undergo
deformation by:
stretching
bending
bending under stretching
stretching at the edge
deep drawing
This information significantly helps process and tool
design engineers predict failure during analysis of sheet
metal forming processes for tool design.
REFERENCES:
Abbaschian, Reed-Hill. Physical
Metallurgy Principles. 4th edition. 2009
Beer & Johnston (2006). Mechanics of
Materials (5th edition). McGraw Hill.
Robert S Williams Metallurgy and
metallurgical engineering series.
McGraw-Hill Book Co; 5th edition (1948).