Workability

Materials
& Design
Materials and Design 27 (2006) 566575
www.elsevier.com/locate/matdes
Workability studies on cold upsetting of AlAl2O3

composite material
R. Narayanasamy
a,*
, T. Ramesh b, K.S. Pandey
Department of Production Engineering, National Institute of Technology, Tiruchirappalli 620 015, Tamilnadu, India
Department of Mechanical Engineering, J.J. College of Engineering and Technology, Tiruchirappalli 620 009, Tamilnadu, India
c
Department of Metallurgical Engineering, National Institute of Technology, Tiruchirappalli 620 015, Tamilnadu, India
Received 16 June 2004; accepted 1 December 2004
Available online 3 February 2005
Abstract
Workability is concerned with the extent to which a material can be deformed in a specic metalworking process without the
initiation of cracks. The ductile fracture of components is the most common mode of cracks in any metalworking processes. Workability is the complex technological concept, depends upon the ductility of the material and the details of the process parameters. An
experimental research work was preformed for the understanding of the working behaviour of AlAl2O3 composite under various
stress state conditions, namely uniaxial, plane and triaxial stress states. Upsetting of AlAl2O3 powder metallurgy compacts with
various aspect ratios and initial preform densities were carried out and the working behaviour of the powder compacts at various
state conditions was computed. The curves plotted for dierent components such as axial strain vs. formability stress index, relative
density vs. axial strain, fracture strain vs. formability stress index and stress ratio parameters vs. axial strain were analyzed, using the
true strains induced during upsetting with the consideration of bulging eect.
2005 Elsevier Ltd. All rights reserved.
Keywords: Upsetting; Workability; Triaxial stress formability stress index; Powder metallurgy and relative density
1. Introduction
Powder metallurgy (P/M) is a highly developed method of manufacturing precision metal parts. Over the last
seven decades, the technology has matured from making
self-lubricating bearings for autos to complex carrier
gear set in automobile transmissions and high strength
powder-forged connecting rods in engines. P/M technology includes the basic steps: mixing of elemental powders, compaction and sintering or heating the shape in
a controlled atmosphere furnace to bond the particles
together metallurgically. After sintering the but prior
*
Corresponding author. Tel.: +91 431 250 1801; fax: 91 431 250
0133.
E-mail addresses: narayan@nitt.edu (R. Narayanasamy), trhashwek@yahoo.co.in (T. Ramesh), pandey@nitt.edu (K.S. Pandey).
0261-3069/$ - see front matter 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2004.12.005
to a specically designed thermal treatment to eect

homogenization, mechanical working is carried out to
introduce the lattice defect which would increase the inter-diusion coecient and to alter the dimensions of
the particles in the compact as well as overall geometry
of the microstructure of the compact. The worldwide
popularity of powder metallurgy lies in the ability of
producing such complex shapes with exact dimensions
with an excellent surface nish of between 32 and 48 micro inches at a very high production rate and low cost.
Workability is the term used to evaluate the capacity
of a material to withstand the induced internal stresses
of forming before the splitting of material occurs. It is
a complex technological concept that depends both
material and process parameters. The workability of a
material purely depends on the amount of ductile
fracture presented in the material. To understand the
R. Narayanasamy et al. / Materials and Design 27 (2006) 566575
workability criteria of any material, a clear concept on

fracture criterion for ductile fracture must be established. Kuhn and Downey [1] investigated the deformation characteristics and the plasticity theory of sintered
powder materials and studied the basic deformation
behaviour of sintered iron powder performing a simple
homogeneous compression tests and also proposed a
plasticity theory relating yield stress and Poissons ratio
to the density. A new yield criterion is also proposed for
the prediction of forming stresses in repressing and in
plane strain compression. A plasticity theory for porous
solids was proposed by Green [2] considering numerous
cracks or voids in the shape of spherical or where the
direction of cracks was completely random. And also
an approximate expression for deformation theory was
also discussed.
Shima and Oyane [3] proposed a plasticity theory for
porous metals of sintered copper with various apparent
densities and the stressstrain curves for pore free copper compacts were also calculated utilizing the basic
equations and compared with the experimental results.
Gurson [4] discussed the continuum theory of ductile
rupture by void nucleation and growth considering yield
criteria and ow rules for porous ductile media and
developed approximate yield criteria and ow rules for
porous ductile materials by showing the role of hydrostatic stress in plastic yield and void growth. Doraivelu
et al. [5] proposed a new yield equation for the P/M
materials and veried experimentally the uniaxial state
of compressive stress using aluminium alloy and the
yield surfaces for various density levels were generated
in a three dimensional principal-stress space with the
help of computer graphics. Lee and Kim [6] proposed
a new form of yield criterion for porous metals having
a variable parameter obtained from the uniaxial relative
yield stress versus density data. Various ductile fracture
criterions were discussed by Hung-Kuk Oh [7] and proposed a new ductile fracture criterion considering the
theory of fracture toughness under dierent mean stress
by conducting a tensile test. The concept of deformation
and fracture of powder metallurgy preform still requires
a considerable amount of investigation. Abdel-Rahman
and El-Sheikh [8] discussed workability criterion of
powder metallurgy compacts and they investigated the
eect of the relative density on the forming limit of P/
M compacts in upsetting. They proposed a workability
factor (b) for describing the eect of the mean stress
and the eective stress with the help of two theories
and they discussed the eect of relative density. Surface
fracture is another mode for the initiation of the crack in
the ductile fracture studies. Dae-Cheol Ko et al. [9] suggested a scheme to simultaneously accomplish both the
prediction of surface fracture initiation and the analysis
of deformation in the axi-symmetric extrusion and simple upsetting of an aluminium alloy. Numerical methods
were used for the prediction of surface fracture initiation
567
and the corresponding level of deformation was experimentally observed. Petruska and Janicek [10] performed
a nite element test on cylindrical specimens with longitudinal surface notch under compression tests with various aspect ratio and frictional conditions for the
evaluation of the ability of various ductile fracture criteria to predict exactly the fracture initiation.
Narayansamy and Ponalagusamy [11] proposed a
mathematical theory of plasticity for compressible powder metallurgy materials. Yield stress values in the case
of simple upsetting compression tests were proposed.
Numerical integration was carried out for the computation of the yield stress. Further, they developed a theory
for the calculation of stresses using the plasticity equations. The plastic upsetting of a solid cylinder between
elastic platens was investigated by Lin [12] and the
spring back eect of the end surfaces of the billet and
the elastic deection of the dies were determined using
a thermo-elasticplastic coupling model. Distributing
of temperature and eective strain were also determined
through nite element approach. A theoretical and
experimental research work was carried out by Gouveia
et al. [13] for the prediction of ductile fracture conducting experiments on powder compacts with various geometrical shapes such as ring, cylindrical, tapered and
anged under several dierent loading conditions. Also,
the experimental work was veried with nite element
codes. Buijk [14] utilized the nite volume method to
study the behaviour of upset forging of cylinders using
rst and second order implementation of the nite volume method and predicted the die load for obtaining
the cylinder upsetting. Narayansamy et al. [15] proposed
a generalized yield criterion considering an-isotropic
parameters for porous sintered powder metallurgy metals and introduced a new ow rule with an-isotropic
parameters for porous metals. Further, they proposed
new generalized yield criteria with ve parameters constants for porous sintered powder metallurgy metals.
Landre et al. [16] discussed the utilization of ductile
fracture criteria in conjunction with the nite element
method and predicted when and where the materials
are likely to fracture during cold forging and validated
their results with experimental data. Continuum damage
mechanics was used by Gupta et al. [17] for the ductile
prediction in axi-symmetric upsetting. A parametric
study was carried out to determine the eect of friction
and height to diameter ratio on the deformation level
which micro crack initiate at the die work interface, centre of the work piece and meridian surfaces.
In this paper, a complete investigation on the workability criteria of AlAl2O3 powder preform compacts
was prepared. Powder metallurgy compacts with various
aspect ratios and initial preform densities were discussed
for studying the behaviour of powder metallurgy compacts under various stress state conditions namely uniaxial, plane and triaxial state of stress. A new strain
568
equation is used including the eect of the bulging during cold upsetting. The curves are plotted for formability stress index and relative density against axial strain
and from which it is concluded that the aspect ratio
and initial preform density plays a major role in the
study of workability criteria.
it strain is the same as the eective strain. It is

determined from:
/eff lnH 0 =H f :
Table 1
Sieve analysis of aluminium powder
2. Theoretical foundations
The mathematical expressions used and proposed for
the determination of various upsetting parameters of
upsetting for various stress state conditions are discussed below:
2.1. Uniaxial stress state condition
In the compression of a P/M part, under frictional
conditions, the average density is increased. Friction enhances densication and at the same time decreases the
height reduction at fracture. The state of stress in a
homogeneous compression process is as follows:
According to Abdel-Rahman and El-Sheikh [8]:
rz reff ; rr rh 0;
Sieve size
Percent distribution (weight)
+150
+125
+106
+90
+75
+63
+53
+45
+38
38
3.60
3.60
2.50
0.71
8.30
9.20
16.70
15.80
3.62
35.71
Apparent density: 1.030 g/cm3.

Flow rate: 32 s/50 g.
Compressibility at pressure of 300 MPa: 2.344 g/cm3.
where rz is the axial stress, re is the eective stress, rr is

the radial stress and rh is the hoop stress.
rm rz =3;
where rm is the mean or hydrostatic stress and the strain

state is,
eh eeff lnDf =D0 and ez lnH f =H 0 ;
where eh is the hoop strain, ez is the axial strain, D0 is the

initial diameter of the compacts, Df is the contact diameter after deformation, H0 is the initial height of the
compacts and Hf is the fracture height of the compacts.
When the compression continues, the nal diameter
increases and the corresponding hoop strain, which is
tensile in nature, also increases until it reaches the fracture limit. Once the fracture is initiated, the forming lim-
Fig. 1. SEM photograph of aluminium powder.
Table 2
Characterization of AlAl2O3 powder compacts
Aspect
ratio
Height
(H0) (mm)
Diameter
(D0) (mm)
Initial preform
density (%)
Compressive
load (MN)
0.35
9.50
9.75
9.80
27.80
27.75
27.75
90
80
75
0.135
0.08
0.055
0.56
16.20
15.40
15.00
27.80
27.75
27.75
90
80
75
0.135
0.08
0.055
0.72
20.00
20.30
19.65
27.80
27.75
27.75
90
80
75
0.135
0.08
0.055

Triaxial Stress State Condition

1.2
Aspect Ratio 0.35, Initial

Fractioanl Preform Density 0.9
1.1

Fractional Preform Density 0.8


0.9

0.8

0.7

Fractional Peform Density 0.75
0.6

0.5
Aspect Raqtio 0.72, Initial

0.4
Aspect Ratio o.72, Initial

Aspect Ratio 0.35, InitialFractional

Preform Density 0.8
1.1

0.9

0.8
Axial Strain (z)
Axial Strain(z)
Power Law Curve Fitting Results

1.2

0.7
0.6
0.5

0.4
0.3
0.3
0.2
0.2
0.1
0.1

0
0
(a)
569
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.1
(b)
Formability Stress Index ()
0.2
0.3
0.4
0.5
0.6
0.7

1.2
Parabolic Curve Fitting Results
1.1

Aspect Ratio 0.35,

InitialFractional Preform Density
0.8
0.9

Axial Strain (z)
0.8
0.7
0.6

0.5

0.4

0.3
0.2
0.1
0
0
(c)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Fig. 2. (a) Axial strain (ez) vs. formability stress index b triaxial stress state condition. (b) Axial strain (ez) vs. formability stress index b triaxial
stress state condition (power law curve tting results). (c) Axial strain (ez) vs. formability stress index b triaxial stress state condition (parabolic
curve tting results).
570
As an evidence of experimental investigation implying the importance of the spherical component of the
stress state on fracture according to Vujovic and Shabaik [18] proposed a parameter called a formability
stress index b given by,
b 3rm =reff :
This index determines the fracture limit as explained

in [18].
where A 2 R2 rh R2 rz 2rh , B 2 R2 rz
R2 rz 2rh , a = Poissons ratio and R = relative
density.
From the above Eq. (10), using the known values of
a, R and rz, the Hoop stress component (rh) can be
determined as follows:
rh 2a R2 =2 R2 2R2 arz :
11
2.2. Plane stress state condition
In the above Eq. (11), the relative density (R) plays a

major role in nding the hoop stress component.
Since rr = rh in case of triaxial stress condition, the
hydrostatic stress is given by,
According to Narayanasamy and Pandey [19], the

state of stress in a plane stress condition is as follows:
rm r1 r2 r3 =3 rz 2rh =3:
reff 0:5 a31 a a2 0:5 rz ;
The eective stress can be determined from the following relation as explained elsewhere [20].
12
where re is the eective stress, a is the Poissons ratio =

(eh/2ez) and rz is the axial stress in upsetting.
Since the radial stress rr is zero at the free surface, it
follows from the ow rule that
r21 r22 r23 R2 r1 r2 r2 r3 r3 r1
rh 1 2a=2 arz
r2eff r2z r2h r2r R2 rz rh rh rr rr rz =2R2 1:
2R2 1r2eff
13
or
and the Hydrostatic stress (rm) is,

rm 1=3rh rz :
The hoop strain (eh) of the compact is determined as

explained elsewhere [18].
eh
ln2D2b
D2c =3D20 ;
where DB is bulged diameter of the compacts, Dc is contact diameter of the compacts and D0 is the initial diameter of the compacts.
2.3. Triaxial stress state condition
According to Narayanasamy and Ponalagusamy [20],
the state of stress in a triaxial stress condition is given as
follows:
a A=B;
10
Since rh = rr

r2eff r2z 2r2h R2 rz rh r2h rz rh =2R2 1
reff

0:5
r2z 2r2h R2 r2h 2rz rh =2R2 1 :
14
3. Experimental details
Atomized aluminium powder was procured and analyzed for its purity and was found to be 99.7%. The
characterization of aluminium and alumina powder
was studied by determining the ow rate, apparent density, tap density and particle size distribution as shown
in Table 1. Fig. 1 shows the SEM photograph of an aluminium powder. A sieve analysis is made to determine
the particle size as stated in Table 1. The compacts were
Table 3
Curve tting results axial strain (ez) vs. formability stress index (b)
Axial strain (ez) vs. formability stress index (b)
Name of the curve
Aspect ratio
Fractional preform density
Equation
R2 value
0.35
0.35
0.35
0.56
0.56
0.56
0.72
0.72
0.72
0.9
0.8
0.75
0.9
0.8
0.75
0.9
0.8
0.75
Power law equation

Y = 66.157X10.032
Y = 9.7037X4.468
Y = 1.8773X1.8058
Y = 30.989X7.6418
Y = 8.712X4.0702
Y = 41.292X4.066
Y = 246.1X11.134
Y = 10.176X4.2095
Y = 138.56X5.22
0.848
0.9444
0.9669
0.9784
0.972
0.7402
0.8638
0.9471
0.5812
X = Formability stress index (b); Y = axial strain (ez).
571
(Parabolic Curve Fitting )




0.95
0.95


0.9

0.85

Relative Density (R)


0.85
0.8
0.75
0.75
0.7
0
(a)


Fractioanl Preform Density 0.75
0.8

0.9
0.2
0.4
0.6
0.8
0.7
0
1.2
0.2
0.4
(b)
Axial Strain (z)
0.6
0.8
1.2
Axial Strain (z)
(Power Law Curve fitting Results)

1

0.95



0.9


0.85

0.8
0.75
0.7
0
(c)
0.2
0.4
0.6
0.8
1.2
Axial Strain (z)
Fig. 3. (a) Relative density (R) vs. axial strain (ez). (b) Relative density (R) vs. axial strain (ez) (parabolic curve tting). (c) Relative density (R) vs.
axial strain (ez) (power law curve tting results).
572
prepared from AlAl2O3 with dierent aspect ratio as

shown in Table 2 with the compacting load range of
0.0550.135 MN in order to obtain the three dierent
initial preform densities, namely, 75%, 80% and 90%
of the theoretical density. The free surfaces of the compacts were coated with ceramics to avoid oxidation during sintering. The ceramic coated compacts were dried at
room temperature and sintered at 550 C for a period of
90 min in an electric mue furnace; then the sintered
compacts were left in the furnace itself and cooled to
room temperature. The compacts were measured for
their heights and diameters and the same recorded.
The deformation of the compact was carried out between two at open dies made from high carbon high
chromium die steel heat treated to Rc 5055 and tempered to Rc 4548 on a hydraulic press of 100 tons
capacity. Each compacts was subjected to the incremental compressive load of two tons and then continued until the appearance of rst visible crack on the free
surface. After each interval of loading dimensional
changes and density measurements were carried out.
4. Results and discussion
Table 4
Curve tting results Relative density (R) vs. axial strain (ez)
Relative density (R)
vs. axial strain (ez)
Name of the curve
Aspect
ratio
Fractional
preform
density
Equation
R2 value
0.35
0.35
0.35
0.56
0.56
0.56
0.72
0.72
0.72
0.9
0.8
0.75
0.9
0.8
0.75
0.9
0.8
0.75
Power law equation

Y = 0.9778X0.0233
Y = 0.9532X0.0392
Y = 0.8878X0.0365
Y = 0.9674X0.0223
Y = 0.9498X0.0426
Y = 0.8676X0.0311
Y = 0.9573X0.0204
Y = 0.9447X0.0415
Y = 0.8626X0.296
0.9219
0.9453
0.912
0.9432
0.954
0.9036
0.9045
0.9411
0.891
0.35
0.35
0.35
0.56
0.56
0.56
0.72
0.72
0.72
0.9
0.8
0.75
0.9
0.8
0.75
0.9
0.8
0.75
Polynomial equation
Y = 0.0812X2 + 0.1615X + 0.9008
Y = 0.1421X2 + 0.2758X + 0.8243
Y = 0.2609X2 + 0.4107X + 0.7581
Y = 0.08 19X2 + 0.1619X + 0.8909
Y = 0.1 141X2 + 0.251X + 0.8199
Y = 0.205X2 + 0.3277X + 0.7605
Y = 0.723X2 + 0.1551X + 0.8835
Y = 0.1222X2 + 0.2627X + 0.8127
Y = 0.213 1X2 + 0.3328X + 0.7563
0.9989
0.9985
0.9974
0.9982
0.9963
0.9994
0.9951
0.994
0.999
X = Axial strain (ez); Y = relative density (R).
1.2
0.8
Fracture Strain (f)
Figs. 2(a)(c) have been plotted between the axial

strain and the formability stress index for the upsetting
of AlAl2O3 powder compacts for the various aspect ratios and three dierent initial preform densities under
triaxial stress state condition. It is observed that the
formability stress index varies with aspect ratio and initial fractional preform density. For the lower aspect ratio and higher initial preform density, the stress
formability stress index takes a very high value. For
compacts of higher aspect ratio and lower initial fractional preform density, the stress formability index value
moves closer to the minimum value. Among curve-tting techniques applied, the parabolic curve tting
expression was found to be the best tted curve for the
plot between the axial strain and the formability stress
index. The power law and the parabolic curve equations
for the plot between the axial strain and formability
stress index are shown in Table 3. It is observed that
the parabolic expressions are best suited for the selected
range of the aspect ratios and initial preform densities,
which give the higher correlation coecient (R). From
Table 3, it is observed that the constant value decreases
with decreasing amount of initial fractional preform
density for the parabolic curve tting. For the compacts
with aspect ratios namely 0.56 and 0.72, the constant
values for X2 term are negative for lower fractional preform densities.
Figs. 3(a)(c) have been plotted between the relative
density and the axial strain for the upsetting of Al
Al2O3 powder compacts for the various aspect ratios
and three dierent initial preform densities under triax-
0.6
0.4
0.2
y = 2.0102x - 0.301
2
R = 0.8573
0
0.3
0.35
0.4
0.45
0.5
0.55
0.6
0.65
0.7
0.75
Fig. 4. Fracture strain (ef) vs. formability stress index (b).
0.8

1
573
0.3
Aspect Ratio 0.35, Initial Preform
Density 90%

Density 90%

Density 80%
0.9

Density 80%

Density 75%
0.25

Densaity 75%
0.8
Density 90%
Aspect Ratio 0.56, Initial Peform

Density 75%
0.6
Density 90%

Preform Density 80%
0.5
Aspect Ratio o.72, Initial Preform

Density 75%
Stress Ratio (m / eff)
0.7
Stress Ratio (r / eff)

Density 90%

Density 80%

Density 80%
0.2

Density 75%

Density 90%
0.15
Preform Density 80%
0.4

Density 75%
0.1
0.3
0.2
0.05
0.1
0
0.7
(a)
0.75
0.8
0.85
0.9
0.95
0.7
(b)
0.75
0.8
0.85
0.9
0.95
1
Density 90%
0.9

Density 80%

Densaity 75%
0.8
Stress Ratio (z / eff)

Density 90%
0.7
Density 80%
0.6
Density 75%

Density 90%
0.5

Preform Density 80%
0.4

Density 75%
0.3
0.2
0.1
0
0.7
(c)
0.75
0.8
0.85
0.9
0.95
Fig. 5. (a) Stress ratio (rr/re) vs. relative density (R). (b) Stress ratio (rm/re) vs. relative density (R). (c) Stress ratio (rz/re) vs. relative density (R).
574
ial stress state condition. It is observed that for the selected range of aspect ratios and initial preform densities, the initiation of the fracture of the compacts has
been observed at a very high strain value for the cases
of the compacts having lower aspect ratios and higher
initial preform densities. Two dierent curve-tting
techniques, namely parabolic and power law expressions, were used and the respective equations determined and the correlation coecient (R) are shown in
Table 4. From Table 4, it is observed that the constant
values decrease with decreasing initial fractional preform density.
Fig. 3(b) shows the parabolic curve tting results
for the plots between the relative density and the axial
strain. The parabolic equation has been found to be
the best curve tting for the compacts having medium
value of aspect ratios and medium initial preform
densities.
Fig. 3(c) shows the power law curve tting results
for the plot between the relative density and the axial
strain. In addition to the parabolic curve tting result,
the power law expression has also been tried and this
shows the best tting results for the compacts having
medium aspect ratios and with the medium initial preform densities. Among both the curve tting results,
the parabolic curve tting expression shows a very
good correlation coecient (minimum of 0.997 and
maximum of 0.998).
Fig. 4 has been drawn between the fracture strain
and the formability stress index for the upsetting of
AlAl2O3 powder compacts for the various aspect
ratios and three dierent initial preform densities under triaxial stress state condition. It is observed that
the fracture strain of the compacts is purely depends
on the aspect ratio and initial preform density. From
this gure, it is noted that for the compacts with higher aspect ratios and higher initial preform densities,
the initiation of crack appeared at a very high fracture
strain. For the case of compacts with lower aspect
ratios and lower initial preform densities, the initiation
of crack readily appeared at a low fracture strain.
Further, it is observed that for the case of compacts
with lower aspect ratios and with very high initial
preform densities a very high fracture strain is
obtained. A straight line tting is used for the plot
between the fracture strain and the formability stress
index and the slope of the straight line is found to
be 2.0335.
Figs. 5(a)(c) have been plotted between the various
stress ratios, namely (rr/re), (rm/re) and (rz/re) and
the relative density (R) for the upsetting of AlAl2O3
powder compacts with various aspect ratios and three
dierent initial preform densities under triaxial stress
state condition. It is observed that a very high stress ratio is obtained for the case of the compacts made with
the lower value of the aspect ratios and very high initial
preform densities. A small value of the stress ratio

parameter is obtained for the case compacts with medium aspect ratios and with lower initial preform
densities.
The curve tted results for axial strain and formability stress index are shown in Table 3. Power law equations and the parabolic curve tting equations are used
for the plot between the axial strain and the formability
stress index and the correlation coecient obtained for
the parabolic curve equations found to be closer to
unity. The curve tted results for the plots between the
relative density and the axial strain are shown in Table
4. It is noted that the parabolic curve tting shows the
best results for all the values of aspect ratios and initial
preform densities. Similarly, the power law curve tting
also shows the best results for compacts with medium
aspect ratios and with medium initial preform densities.
From comparison of the above curve tting
results, the parabolic one gives better correlation
coecient.
5. Conclusion
The stress formability index increases with increase in
initial preform fractional density and lower the aspect
ratios.
Parabolic curve tting shows the better results for the
plot between the axial strain and the stress formability index.
Among the curve ttings, the parabolic type one
shows a very good correlation coecient (minimum
of 0.997 and maximum of 0.998) for the plot between
the relative density and the axial strain.
For the compacts with higher value of the aspect ratio
and with higher initial preform density, the initiation
of crack appeared at a very high fracture strain
For the case of the compacts with lower value of
the aspect ratio and with very high initial preform
density, a very high stress ratio parameter is
obtained.
References
[1] Kuhn HA, Downey CL. Deformation characteristics and plasticity theory of sintered powder materials. Int J Powder Metall
1971;7(1):1525.
[2] Green RJ. A plasticity theory for porous solids. Int J Mech Sci
1972;14:21524.
[3] Shima S, Oyane M. Plasticity theory for porous metals. Int J
Mech Sci 1976;18:28591.
[4] Gurson AL. Continuum theory of ductile rupture by void
nucleation and growth: Part I Yield criteria and ow rules for
porous ductile media. J Eng Mater Technol Trans ASME
1977:19.

[5] Doraivelu SM, Gegel HL, Gunasekara JS, Malas JC, Morgan JT.
A new yield function for compressible P/M materials. Int J Mech
Sci 1984;26(9/10):52735.
[6] Lee DS, Kim HS. Plastic yield behaviour of porous metals. Int J
Powder Metall 1992;35:2759.
[7] Oh Hung-Kuk. Determination of ductile fracture at any stress
state by means of the uniaxial tensile test. J Mater Process Tech
1995;53:5827.
[8] Abdel-Rahman M, El-Sheikh. Workability in forging of powder
metallurgy compacts. J Mater Process Tech 1995;54:97102.
[9] Ko Dae-Cheol, Kim Byung-Min, Choi Jae-Chan. Prediction of
surface fracture initiation in the axisymmetric extrusion and
simple upsetting of an aluminium alloy. J Mater Process Tech
1996;62:16674.
[10] Petruska, Janicek L. Computationally experimental workability
determination of compressed cylindrical specimen with surface
defects. J Mater Process Tech 1998;8081:5728.
[11] Narayansamy R, Ponalagusamy R. A mathematical theory of
plasticity for compressible P/M materials. J Mater Process Tech
1999;86:15962.
[12] Lin SY. Upsetting of cylindrical specimen between elastic tools. J
Mater Process Tech 1999;86:7380.
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[13] Gouveia BPPA, Rodrigues JMC, Martins PAF. Ductile fracture

in metalworking: experimental and theoretical research. J Mater
Process Tech 2000;101:5263.
[14] Buijk AJ. Application of the nite volume method to upset
forging of cylinders, Forging fair. Columbus, OH; 2000.
[15] Narayanasamy R, Ponalagusamy R, Subramanian KR. Generalized yield criteria of porous sintered powder metallurgy metals. J
Mater Process Tech 2001;110:1825.
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On the utilization of ductile fracture in cold forging. Finite Elem
Anal Des 2003;39:17586.
[17] Gupta S, Venkata Reddy N, Dixit PM. Ductile fracture prediction in axisymmetric upsetting using continuum damage mechanics. J Mater Process Tech 2003;141:25665.
[18] Vujovic V, Shabaik AH. A new workability criterion for ductile
metals. J Eng Mater Tech 1986;108:2459.
[19] Narayansamy R, Pandey KS. A study of barreling aspects on P/M
iron preforms during hot upset forming. J Mater Process Tech
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015, Tamilnadu, India; 2001.

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Materials

Workability studies on cold upsetting of AlAl2O3

, T. Ramesh b, K.S. Pandey

to a specically designed thermal treatment to eect

R. Narayanasamy et al. / Materials and Design 27 (2006) 566575

workability criteria of any material, a clear concept on

R. Narayanasamy et al. / Materials and Design 27 (2006) 566575

it strain is the same as the eective strain. It is

Percent distribution (weight)

Apparent density: 1.030 g/cm3.

where rz is the axial stress, re is the eective stress, rr is

where rm is the mean or hydrostatic stress and the strain

where eh is the hoop strain, ez is the axial strain, D0 is the

Fig. 1. SEM photograph of aluminium powder.

R. Narayanasamy et al. / Materials and Design 27 (2006) 566575

Triaxial Stress State Condition

Aspect Ratio 0.35, Initial

Aspect Ratio 0.35, Initial

Aspect Ratio 0.35, Initial

Aspect Ratio 0.35, Initial

Aspect Ratio 0.56, Initial

Aspect Ratio 0.56, Initial

Aspect Ratio 0.56, Initial

Aspect Ratio 0.72, Initial

Aspect Raqtio 0.72, Initial

Aspect Ratio o.72, Initial

Aspect Ratio 0.35, InitialFractional

Aspect Ratio 0.35, Initial

Aspect Ratio 0.56, Initial

Axial Strain (z)

Power Law Curve Fitting Results

Aspect Ratio 0.56, Initial

Aspect Raqtio 0.72, Initial

Aspect Ratio o.72, Initial

Formability Stress Index ()

Formability Stress Index ()

Triaxial Stress State Condition

Parabolic Curve Fitting Results

Aspect Ratio 0.35, Initial

Aspect Ratio 0.35,

Aspect Ratio 0.35, Initial

Axial Strain (z)

Aspect Ratio 0.56, Initial

Aspect Ratio 0.72, Initial

Aspect Ratio o.72, Initial

Formability Stress Index ()

R. Narayanasamy et al. / Materials and Design 27 (2006) 566575

This index determines the fracture limit as explained

2.2. Plane stress state condition

In the above Eq. (11), the relative density (R) plays a

According to Narayanasamy and Pandey [19], the

rm r1 r2 r3 =3 rz 2rh =3:

reff 0:5 a31 a a2 0:5 rz ;

where re is the eective stress, a is the Poissons ratio =

r21 r22 r23 R2 r1 r2 r2 r3 r3 r1

r2eff r2z r2h r2r R2 rz rh rh rr rr rz =2R2 1:

and the Hydrostatic stress (rm) is,

The hoop strain (eh) of the compact is determined as

Name of the curve

Fractional preform density

Power law equation

X = Formability stress index (b); Y = axial strain (ez).

R. Narayanasamy et al. / Materials and Design 27 (2006) 566575

(Parabolic Curve Fitting )