FundamentalofMetalWorking

Classificationofmetalworkingprocesses
Direct-compression-type processes
Indirect-compression processes p p
Tension type processes
Bending processes Bending processes
Shearing processes
Directcompression type :
The applied force is normal to
th di ti f th t l fl i the direction of the metal flow in
compression, i.e., forging and
rolling processes
Indirect compression type processes: Indirectcompression type processes:
the primary forces are frequently tensile, with indirect compressive
forces developed by the reaction of the work piece. The metal flow is
th f d th bi d t t t i t i i d i therefore under the combined stress state, i.e., extrusion, wiredrawing,
tube drawing.
Tension type processes:
th li d f i t il i t t hi the applied force is tensile, i.e., stretching
forming.
Bending processes:
the applied force involves the application
of bending moments to the sheet.
Shearing processes:
the applied force involves the application
of shearing forces of sufficient magnitude g g
to rupture the metal in the plane of shear.
Classificationbysubgroups
Mechanics of metal working
Metal working occurs due to plastic deformation which is
associated with analysis of complex stress distribution.
require simplification. q p
Only (large) plastic strain is considered while elastic strain is very
small and can be neglected.
Strain hardening is often neglected Strain hardening is often neglected.
Metal is considered to be isotropic and homogeneous
In actual situation, plastic deformation is not uniform and also have
frictions Hence need to simplify the stress analysis in order to frictions. Hence need to simplify the stress analysis in order to
determine the force required to produce a given amount of
deformation for the product with the required shape and dimensions.
Required theory of plasticity.
For plastic deformation, a constant-volume relationship is required.
In metalworking, compressive stress and strain are predominated.
If bl k f i i i l h i h h i d h h i l i If a block of initial height ho is compressed to h1, the axial compressive
strain will be:
True strain Truestrain,
Engineering
strain,
Note:thecalculatedstrainisnegativecompressivestrains
Theconventionisreversedinmetalworkingproblems,sothatcompressive
stressesandstrainsaredefinedaspositive.
Note: e is used as strain in deformation process Note:e
c
isusedasstrainindeformationprocess.
Andthefractionalreduction
(reductionofarea)inmetalworking
deformation is given by deformationisgivenby
Fromtheconstantvolumerelation