Lecture 30: An Application of Slipline

Fields Plane-Strain Extrusion

Jayadeep U. B.
Dept. of Mechanical Engg., NIT Calicut.
 Introduction
In this lecture, we consider an application of slipline field analysis
plane-strain extrusion.
In plane strain extrusion, a wide strip is extruded through a rigid
frictionless die using a rigid punch, to reduce its thickness.
The punch geometry is assumed to be such that the slipline field
for the deformation zone comprises of a constant pressure zone
(straight sliplines) and a centered fan.
A special case of this geometry (r = 50%) is shown in next slide.
We discuss the hodograph for this process, and illustrate how it
can be used for understanding the energy dissipation and metal
distortion analysis.

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 Plane-strain Extrusion: Slipline Field

Slipline field for the special case of r = 50% and angle = 30o.
This is a special case of the more general problem, which can be
represented as a constant pressure zone and a centered fan, where:
3 ME6302 Metal Forming r = 2sin (1 + 2sin )
 Mohrs Circles and Force Balance Along
the Die Wall

(b) Mohrs circle along OC, (c) Mohrs circle along OB and (d)
Force balance along the die wall.
In this problem, we shall use direction 3 to indicate the smallest
principal stress direction.
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 Slipline Field Analysis
At the exit, 1 = x = 0 and y is compressive.
Hence, OC is a -line and ( z )OC = k
Rotating through an angle of /6 on an -line, we get:
( z )OB = k + 2k ( 6 )
Pressure is same throughout triangle ABO. So, p ABO = k + 2k ( 6 )
Pressure on die wall, p = p ABO + k = 2k (1 + 6 )
Force on the die wall, F = p ( OA ) = p r sin = p
We get: Fx = F sin = pe (1) pe 2k = 0.5 (1 + 6 )
For the more general case (H.W.):
pe 2k = r (1 + ) ; where r = 2sin (1 + 2sin )

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 Geometry of Slipline Field for More
General Case

Note: OB and AB are not necessarily horizontal and vertical

respectively, even though they appear to be so.
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 Slipline Field and Hodograph

On entering the triangle ABO, the velocity should suddenly change

from horizontal to that parallel to AO.
Discontinuous velocity change exists along BC.
Another discontinuous velocity change to horizontal occurs along OC.
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 Energy Dissipation
Homogeneous work, wi = = 2k ln 1 (1 r )
Actual work is wa = pe. Hence deformation efficiency,
= wi wa = ln 1 (1 r ) r (1 + )
Assuming the initial velocity to be 1, all the velocity
discontinuities are of magnitude 1 2 (Refer the hodograph).
So the energy dissipation in these discontinuities is:
k ( AB VAB
*
+ BC VBC*
+ OC VOC*
) = ( 0.5 + 0.5 + 12) k = 1.262k
We have, pe = 1.542k
Therefore 1.262/1.542 = 82% of energy is dissipated along these
discontinuities. Where does the remaining energy go?

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Metal
Distortion
Analysis
(a) Slipline field (b) Hodograph
Distortion of
metal can be
determined from
a slipline field and
its hodograph.
As an example,
consider a Plane-
strain extrusion
through a square
die:
9 ME6302 Metal Forming (c) Predicted Distortion
 Metal Distortion Analysis Contd.
The triangle right to AO is a dead metal zone.
Any metal element entering the field suffers a discontinuity
parallel to the arc at the point of entry.
For example, the element entering the field at A suffers the
velocity discontinuity VA* parallel to the arc at A.
All the velocity discontinuities are of equal magnitude.
There is also a velocity discontinuity along GO so that the exit
velocity is axial (horizontal ) direction.
Stream lines can be drawn for each particle as shown in figure (c).
By considering a vertical grid line, and following the displacement
at each point in the line, distortion of metal can be established.
It can be seen that distortion is the highest at the surface.
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 References
Chakrabarty, J., Theory of plasticity, Butterworth-Heinemann.
Hosford, W.F. and Caddell, R.M., Metal Forming,
Cambridge University Press.
Dieter, G.E., Mechanical Metallurgy, McGraw Hill.
Hoffman, O. and Sachs, G., Introduction to the Theory of
Plasticity for Engineers, McGraw-Hill Book Company.
Hill, R., The Mathematical Theory of Plasticity, Oxford University
Press.
Johnson ,W. and Mellor, P.B., Plasticity for Mechanical
Engineers, van Nostrand Company Ltd.

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