Chapter 19 BULK DEFORMATION

PROCESSES IN METAL WORKING

The four basic bulk deformation processes
 Rolling
 Forging
 Extrusion and
 Wire and bar drawing
Rolling
Rolling is a deformation process in which the thickness of the work is reduced by comprehensive
forces exerted by two opposing rolls.
 Flat rolling and its analysis
d=
  t0-tf ------(19.1) -)
   --------(19.11)
Where, d = draft Where, L = contact length
t0 = starting thickness
wL ---------(19.10)
tf= final thickness
Where, F = rolling force
dmax = --------(19.8)
Where, dmax = maximum draft w = width
µ = coefficient of friction ----------(19.12)
R = rolling radius Where, T = torque
ε = ln -------(19.6) -----------(19.13)
Where, Ɛ = true strain
Where P = power
------(19.7)
N = rotational speed
Where = average flow stress
K = the strength coefficient
n = the strain hardening exponent
Q. A 300-mm-wide strip 25-mm thick is fed through a rolling mill with two powered
rolls each of radius 250 mm. The work thickness is to be reduced to 22 mm in one pass at
a roll speed of 50 rev/min. The work material has a flow curve defined by K 275 MPa
and n 0.15, and the coefficient of friction between the rolls and the work is assumed to be
0.12. Determine if the friction is sufficient to permit the rolling operation to be
accomplished. If so, calculate the roll force, torque, and horsepower.
     
Solution ε = ln = 0.128
w = 300mm
t0 = 25mm = 175.7 Mpa
tf = 22mm Rolling force, wL = 1444786 N
R = 250mm
N = 50rpm Torque, = 19786 Nm
K = 275MPa Power, = 12432086 Nm/min
n = 0.15
µ = 0.12 = 207201 Nm/s
F,T,HP = ?
HP = = 278hp
d= t0-tf = 3mm
dmax = = 3.6mm
- ) = 27.4mm
Forging
Forging is a deformation process in which the work is compressed between two dies using either impact
or gradual pressure to form the part.
 
Q. A cylindrical workpiece is subjected to a cold upset forging operation. The starting piece
is 75 mm in height and 50 mm in diameter. It is reduced in the operation to a height of 36
mm. The work material has a flow curve defined by K 350 MPaand n 0.17. Assume a
coefficient of friction of 0.1. Determine the force as the process begins, at intermediate
heights of 62 mm, 49 mm, and at the final height of 36 mm.
  