Pdf chapter 1 bulk deformation processes geeteu mech. Page 1 of 35 chapter 1 bulk deformation processes metal forming processes are. Deformation processing metalworking processes are commonly classi. Semiatin, air force research laboratory, materials and manufacturing directorate metalworking consists of deformation processes in which a metal billet or blank is shapedbytoolsordies. Pdf introduction to bulkforming processes semantic. In this fundamentals of modern manufacturing materials. 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. 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. Tests for overstressing of critical corners in the combined slipline field are carried out using hills theorem on the maximum intensity of stress singularities. Stresses beyond yield strength of the workpiece material is required.
The surface areatovolume ratio of the starting metal is high. Modeling the joint of toolwork interface friction and. Forging is a metalworking process where a workpiece is shaped by compressive forces using. The possibility of predicting the onset of fracture in bulk deformation processes from ductility parameters determined in simple tests was investigated by performing uniaxial tension, planestrain. Primary working operations break ingot down into shapes such as slabs, plates, and billits forging, rolling, and extrusion. The term bulk deformation implies large amounts of material movement, such as in hot rolling or. 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. Bulk deformation process used to form threads on cylindrical parts by rolling. Plastic deformation penetration thickness fracture shearing. All these processes give a very high plastic deformation to the materials as the strain rate involved in these processes are considerable high. Chapter 19bulk deformation processes in metal working. The generic bulk forming processes are forging, rolling, extrusion and drawing. Primary metalworking processes, such as the bulk deformation pro cesses used to conduct the initial breakdown of cast ingots, are always conducted hot. 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 processes free download as pdf file. Manufacturing process ii fundamentals of metal forming 1. Thedesignandcontrolof such processes depend on the characteristics of the workpiece material, the conditions at the. Reasons why the bulk deformation processes are important include the following. 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. 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. It is used to make a variety of highstrength components for automotive, aerospace, and other applications. These processes involve a large amount of plastic deformation.
The surface of the metal work piece is positioned parallel to the dividing line of the forging. New processes that include a number of novel techniques such as advanced roll forming methods, equalchannel angular extrusion, and incremental forging. Bulk deformation process rolling metalworking extrusion. Compressive deformation process in which the thickness of a plate is reduced by squeezing it through two rotating cylindrical rolls. View test prep final exam equation sheet page 1 from me 381 at university of louisville. Forging is a high strain rate process where material is shaped under the effect of impact load or pressure. Deformation processes can be conveniently classified into bulkforming processes. 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. Bulk deformation processes forging rolling metalworking. These processes work by stressing metal sufficiently to cause plastic flow into desired shape. Cold or hot bulk deformation processes like rolling, drawing, extruding, and forging which involve large scale plastic deformation are used for this purpose. 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. Metalworking processes are commonly classified as either hot working or cold working operations. Metalworking lubricants are applied to toolwork interface in many forming operations to reduce harmful effects of friction benefits.
Primary metalworking processes, such as the bulk deformation processes used to conduct the initial breakdown of cast ingots, are always conducted hot. Blanking shearing a closed outline desired part called blank punching sheared part is slag or scrap and remaining stock is a desired part. Metal forming operations which cause significant shape change by deformation in metal parts whose initial form is bulk rather than sheet. Metal forming operations which cause significant shape change by deformation in metal parts whose initial form is bulk rather than sheet starting forms. Deformation processes can be conveniently classified into bulkforming processes e. Rollingdeformation process in which work thickness is reducedby. The miscellaneous processes within the sheet metalworking classification in. Metal forming processes indian institute of technology.
The term bulk deformation implies large amounts of. 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. Deformation processes can be conveniently classified into bulk forming processes e. Bulk deformation processesin metalworkingrollingother deformation.
Metal formability in bulk deformation processes request pdf. Chapter 19 bulk deformation processes in metalworking. 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. Application of bulk deformation methods for microstructural and material property improvement and residual stress and distortion control in additively manufactured components. Being above the recrystallization temperature allows the material to recrystallize during deformation. These processes work by stressing metal sufficiently to. Metal forming study notes for mechanical engineering. Book download link provided by engineering study material esm. 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.
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