Fundamentals ofMetal Forming.ppt

* ME 482 - Manufacturing Systems * ME 582 - Manufacturing Systems Fundamentals of Metal Forming Fundamentals of Metal Forming Bulk deformation vs Sheetmetal working Bulk deformation * Low surface area to volume ratios * Operations increase surface area to volume ratios Operations are: rolling extrusion forging drawing This group of machines - which are over a half mile long - roll the slab into sheet steel using tremendous pressure. Aluminum extrudate – a simple angled shape. The die shown is more complex. Fundamentals of Metal Forming Bulk deformation Rolling characteristics  * compressive deformation * 2 or more rolls * strong frictional relationship Extrusion characteristics  * compressive deformation * force metal through die opening * strong frictional relationship * hot and cold working process Fundamentals of Metal Forming Sheet metalworking Characterized by: * large surface area to volume ratios * little ratio change after process * machines called presses * parts called stampings * tools are punch and die  Operations:  bending drawing shearing Material Behavior – Flow Stress = K en Concept of flow stress, Yf – the instantaneous stress required to deform the material Yf = K en Process force considerations: * during compression, determine instantaneous force from Yf * max force is often all that is required, typically at end of stroke * force analysis may be based on average stresses and strains Average flow stress = Yf = K en /(1 + n) Fundamentals of Metal Forming Temperature and Metal Forming K and n depend on working temperature, characterized by 3 ranges: Cold working Warm working Hot working Fundamentals of Metal Forming Temperature and Metal Forming – cold working Advantages: * good accuracy and tolerances * better surface finish * strain hardening increases strength and hardness * directional properties * energy economy Disadvantages: * higher forces/power *