Li, national university of singapore abstract asperity interaction models have been developed using the slipline field theory to explain the role of tool surface roughness, lubrication condition, and apparent contact. Metal forming operations which cause significant shape change by deformation in metal parts whose initial form is bulk rather than sheet starting forms. Miscellaneous processes shearing processes deep or cup drawing sheet metalworking bending operations wire and bar drawing extrusion processes forging processes bulk deformation rolling processes metal forming figure 18. Plastic deformation penetration thickness fracture shearing. Volume 14a is an indispensable reference for manufacturing, materials, and design engineers. Sheet metalworking forming and related operations performed on metal sheets, strips, and coils high surface area. Bulk deformation 3262017 2 metal forming operations which cause significant shape change by deformation in metal parts whose initial form is bulk rather than sheet. View test prep final exam equation sheet page 1 from me 381 at university of louisville. New processes that include a number of novel techniques such as advanced roll forming methods, equalchannel angular extrusion, and incremental forging. Deformation processes can be conveniently classified into bulk forming processes e. The miscellaneous processes within the sheet metalworking classification in. Pdf chapter 1 bulk deformation processes geeteu mech. Thedesignandcontrolof such processes depend on the characteristics of the workpiece material, the conditions at the. Bulk deformation process hot working of metals hot working is defined as the process of altering the shape or size of a metal by plastic deformation with the temperature above the recrystallisation point.
Bulk deformation processesin metalworkingrollingother deformation. Bulk deformation processes free download as pdf file. The term bulk deformation implies large amounts of. Metalworking processes are commonly classified as either hot working or cold working operations. Rollingdeformation process in which work thickness is reducedby.
Deformation processes can be conveniently classified into bulkforming processes e. The surface areatovolume ratio of the starting metal is high. Application of bulk deformation methods for microstructural and material property improvement and residual stress and distortion control in additively manufactured components. Tests for overstressing of critical corners in the combined slipline field are carried out using hills theorem on the maximum intensity of stress singularities.
Secondary working operations involve further processing. Metal forming operations which cause significant shape change by deformation in metal parts whose initial form is bulk rather than sheet. Metal formability in bulk deformation processes request pdf. In both cases, the surfaces of the deforming material and of the tools are usually in contact, and friction between them has a major influence. These processes work by stressing metal sufficiently to. Forming limit diagrams, in combination with strain analysis of the process of interest, provide a technique for refined solution of workability problems in complex deformation. The design and control of such processes depend on the characteristics of the workpiece material, the conditions at the toolworkpiece interface, the mechanics of plastic deformation metal flow, the equipment used, and the finishedproduct requirements. Metalworking lubricants are applied to toolwork interface in many forming operations to reduce harmful effects of friction benefits. All these processes give a very high plastic deformation to the materials as the strain rate involved in these processes are considerable high. Bulk deformation processes in metalworking 1 me 350 lecture 22 chapter 19. The term bulk deformation implies large amounts of material movement, such as in hot rolling or.
Modeling the joint of toolwork interface friction and. Bulk deformation process rolling metalworking extrusion. Primary metalworking processes, such as the bulk deformation processes used to conduct the initial breakdown of cast ingots, are always conducted hot. Cold or hot bulk deformation processes like rolling, drawing, extruding, and forging which involve large scale plastic deformation are used for this purpose. Bulk deformation process used to form threads on cylindrical parts by rolling. The joint of toolwork interface friction and work material bulk deformation is thus modelled by the combined slipline field for the interface friction and the bulk deformation. Processes for new materials such as structuralintermetallic alloys and. Pdf introduction to bulkforming processes semantic. Stresses beyond yield strength of the workpiece material is required. The generic bulk forming processes are forging, rolling, extrusion and drawing. Metal forming study notes for mechanical engineering. Reasons why the bulk deformation processes are important include the following. Deformation processing metalworking processes are commonly classi. Being above the recrystallization temperature allows the material to recrystallize during deformation.
Page 1 of 35 chapter 1 bulk deformation processes metal forming processes are. The surface of the metal work piece is positioned parallel to the dividing line of the forging. Identifying the stresses on an element slab is the first step in the slab method of analysis of metalworking processes. Primary metalworking processes, such as the bulk deformation pro cesses used to conduct the initial breakdown of cast ingots, are always conducted hot.
Chapter 19 bulk deformation processes in metalworking. Forging is a metalworking process where a workpiece is shaped by compressive forces using. Bulk deformation metal forming operations which cause significant shape change by deformation in metal parts whose initial form is bulk rather than sheet starting forms. Bulk deformation processes forging rolling metalworking.
Sheet metalworking processes are forming and cutting operations performed on metal sheets, strips, and coils. It discusses the various classes of deformation processes to illustrate their impacts on product design while taking advantage of the benefits of deformation processing. Metal forming processes indian institute of technology. Chapter bulk deformation processes in metalworking opendie forging ln where is true strain, h is. Forging is a high strain rate process where material is shaped under the effect of impact load or pressure.
These processes work by stressing metal sufficiently to cause plastic flow into desired shape. Semiatin, air force research laboratory, materials and manufacturing directorate metalworking consists of deformation processes in which a metal billet or blank is shapedbytoolsordies. Download fundamentals of modern manufacturing materials. Chapter 19bulk deformation processes in metal working. Unlike sheet metal working where the changes in thickness are small, bulk deformation processes cause large changes in thickness, diameter, or other dimensions of the cast metal forms. In this fundamentals of modern manufacturing materials. Deformation processes can be conveniently classified into bulkforming processes. Manufacturing process ii fundamentals of metal forming 1. In coining, pressure is applied to a portion or the entire surface of a forging. It provides comprehensive coverage and essential technical information on the processdesign relationships that are needed to select and control metalworking operations that produce shapes from forging, extrusion, drawing, and rolling operations. These processes involve a large amount of plastic deformation.