Rotary Tool Motion Forming by Bending Joggling Twisting Forming by Shear Metalforming 16 Classification Metal Forming Processes Chapter I: Introduction Metal Forming Processes Bulk Formi
Trang 1THEORY OF PLASTICITY
and ITS APPLICATIONS
INSTITUTE OF METAL FORMING
This Script has been given for Master Course “Mold and Die Engineering” in KUAS.
Content
Chapter I: Introduction
Chapter II: Metallurgical Fundamentals
Chapter III: Strain
Chapter IV: Stress
Chapter V: Yield Criteria
Chapter VI: Flow Rule
Chapter VII: Flow Curve
Chapter VII: Analysis Methods
Extra Chapt FEM Simulation
Chapter IX: Bulk Forming Processes
Chapter X: Sheet Forming Processes
TOTAL LECTURE PERIOD: 8 W
Trang 2Content
• Classification of Manufacturing Processes
• Advantages of Metalforming Processes
• Classification of Metalforming Processes
• Examples of Metalforming Processes
Trang 3Manufacturing Processes
Manufacturing processes produce solid bodies with given
geometry and given properties
Chapter I: Introduction
Creation of
Cohesion
Maintenance of Cohesion
2 Deforming 3 Separating 4 Joining
6 Changing Material Properties Rearrangement
of Particles
Removal of Particles
Addition of Particles
Maintenance of Cohesion: Duy trì sự liên kết
Manufacturing Processes
1 Primary Forming: Casting, Powder Metallurgy
2 Deforming:Metal Forming Processes
(Bulk and Sheet Forming)
3 Separating: Machining (with Cutting Tool
or with Abrasive Tool),Non-Traditional Machining (Laser)
4 Joining: Welding, Joining
5 Coating: Various
6 Changing Material Properties: Heat Treatments
(temper, blank a fire)
Trang 4Jioning with rivet
Coating of TiN by method PVD
Thremal treatment
Welding
Manufacturing Processes
Trang 5Drawing of car body parts Car body parts
Parts of machines Hollow parts used in conduit of oil or gas
Manufacturing Processes
Basic Question of Manufacturing
How can we manufacture a technical product with given
specific dimensional and shape tolerances, given surface
structure and given material properties most economically?
Trang 6Comparision of Machining and
Metalforming
– Metalforming: stresses between 50 to 2500 MPa,
forming forces are upto 75,000 tons
– Metal cutting: Forces about 2 to 20 tons
certain tolerances
properties of the product (especially for
dynamic loadings)
Chapter I: Introduction
Trang 7Grain Flow Comparison
(a) casting, (b) machining, (c) forging
Fiber/Structure of a Drive Shaft
after the Extrusion
Definition of Metal Forming
Metalforming bases on plastic deformation
of metal.
Metalforming is the manufacturing by
plastic (permanent) change of the form of a
solid body by preserving (duy trì) both the
mass and the cohesion.
Trang 8Classification Metal Forming Processes
Chapter I: Introduction
By the primary stress
in the deformation zone.
Further classification by tics, tool geometry and workpiece geometry leading to more than 200 basic processes!
Flange Forming Upset Bulging
B w Linear Tool Motion
B w Rotary Tool Motion
Forming by Bending
Joggling
Twisting
Forming by Shear Metalforming
16
Classification Metal Forming Processes
Chapter I: Introduction
Metal Forming Processes
Bulk Forming Processes Sheet Forming Processes
• Spatial workpieces
• Large changes in cross-section
& large changes in thicknesses
• Material flows in all directions
• Generally multi-axial compressive
stress states
• Larger relative forces
• Planar workpieces (sheets, plates)
• Hollow pieces with almost constant wall thickness
• Generally two-axial stress states:
tensile-tensile/tensile-compressive
Trang 9Classification Metal Forming Processes
Chapter I: Introduction
Bulk Forming Processes
Steady-State Processes Non-Steady-State Processes
Deformation patterns are
Upsetting, forging, extrusion
Classification Metal Forming Processes
Metal Forming Processes
Cold Forming Warm Forming Hot Forming
Steel: Room Temperature
Forming above room temperature
(everyday sense) Forming above the recry- stallization temperature
Steel: 1150-1250 o C
Forming above room temperature
(everyday sense) Forming below or around the recrystallization temperature
Steel: 750-950 o C
Trang 10• Initial temperature of workpiece before forming
• Average temperature of workpiece after forming
• Surface temperature of workpiece after forming
• Highest temperature of workpiece during forming
• Average temperature of tools
• Highest temperature of tool-interface during forming
• Initial temperature of tool
Chapter I: Introduction
Notice temperature by forming process!!!
Trang 11Heating Processes
Chapter I: Introduction
Heating Processes:
• Heating before forming (a)
• Self-heating of workpiece due to
Examples of Metalforming Processes:
Compressive Forming
Upsetting:
Impression Die Forging:
Trang 12Open die forging
Impression Die Forging
Trang 13Upsetting of Head’s Bolt
Examples of Metalforming Processes:
Compressive Forming
Heading (Upsetting)Forward
Extrusion
Backward Can Extrusion
Trang 14Inner Race:
Cold Lateral Extrusion Bevel Gears: Cold Lateral Extrusion
Trang 17Design a model of spinning machine to producing of bottles
for high pressure gas
Trang 18Examples of Metalforming Processes:
Combined Tensile & Compressive Forming
Spinning:
Chapter I: Introduction
1 Disc Blank 2 Spinning Roller 3 Mandrel 4 Clamping Plate 5 Blank Support Unit
6 Trimming Plate 7 Spindle 8 Cross Slide 9 Tailstock
Orbit motion of Spinning roller
Trang 19Examples of Metalforming Processes:
Combined Tensile & Compressive Forming
Spinning:
Chapter I: Introduction
Axis-symmetric Parts
See some movies !
Examples of Metalforming Processes:
Combined Tensile & Compressive Forming
Trang 20Examples of Metalforming Processes:
Combined Tensile & Compressive Forming
Trang 21Examples of Metalforming Processes:
Combined Tensile & Compressive Forming
Deep drawing:
Courtesy of University of Munich
Chapter I: Introduction
Examples of Metalforming Processes:
Combined Tensile & Compressive Forming
Deep drawing examples (Sidepanel – ULSAB) Courtesy Niels Bay
Trang 22Examples of Metalforming Processes:
Combined Tensile & Compressive Forming
Deep drawing examples
Chapter I: Introduction
Courtesy Niels BayProducts: pot, pan, basin
44
Examples of Metalforming Processes:
Combined Tensile & Compressive Forming
Chapter I: IntroductionFlange Forming:
Trang 23Examples of Metalforming Processes:
Combined Tensile & Compressive Forming
Chapter I: Introduction
Hydro-forming:
1 Closing of the press 2 Filling the water
3 Pressurizing/compressing 4 Opening the press
Courtesy
of Schuler
Examples of Metalforming Processes:
Combined Tensile & Compressive Forming
Cap for pump housing (IPL, Grundfos)
Trang 24Examples of Metalforming Processes:
Combined Tensile & Compressive Forming
Trang 25Bending Machines
Stretching Machines
Nonlinear Relative Motion
of the Tools
Forming Medium
Forming Energy
Special Machines Forming Machines
by K Lange
Metalforming Machines: Examples (1)
Compressed air hammer
Hydraulich hammer
Trang 27Hydraulic press machine
Hydraulic press machine (transfer press)
Trang 28Courtesy Eres Söylemez
Metalforming Machines: Examples (3)
Mechanical PressHydraulic Press
Trang 29D©y chuyÒn s¶n xuÊt trôc khuûu
Roller for Sheet Rolling mill
Trang 30Rolling mill
60
Rolling
Trang 31Metalforming System
System items:
1 Deformation zone
2 Properties before deformation
3 Properties after deformation