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Plasticity Engineering: - Fundamentals & Applications of Metal Forming Processes

This document provides an introduction to the subject of Plasticity Engineering. It will cover the fundamentals and applications of metal forming processes. The primary goals are to produce desired shape changes in metals and understand how processing affects material properties. The course will examine physical metallurgy, mechanics of plasticity theory, stress and strain analysis, yield criteria, work hardening, and more. Typical metal forming processes to be discussed include forging, rolling, extrusion, sheet metal forming techniques, and others. The interaction between tools and metals during plastic deformation will be analyzed mathematically.

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Dennis Padec Bwochengo
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89 views

Plasticity Engineering: - Fundamentals & Applications of Metal Forming Processes

This document provides an introduction to the subject of Plasticity Engineering. It will cover the fundamentals and applications of metal forming processes. The primary goals are to produce desired shape changes in metals and understand how processing affects material properties. The course will examine physical metallurgy, mechanics of plasticity theory, stress and strain analysis, yield criteria, work hardening, and more. Typical metal forming processes to be discussed include forging, rolling, extrusion, sheet metal forming techniques, and others. The interaction between tools and metals during plastic deformation will be analyzed mathematically.

Uploaded by

Dennis Padec Bwochengo
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Plasticity Engineering

-Fundamentals & applications of metal forming processes

Instructor: Qing Zhou Dr.

1 Introduction
1.1 Definition and scope of the subject

The primary objective of metal-forming operations is to produce a desired shape change. Two major concerns of the engineer are the forces required for the operation and the properties of the work material. It must be recognized that material properties affect the process, and processing alters the material properties.

When a solid metal is subjected to a load of small magnitude, it deforms elastically such that the strain is directly proportional to the stress and when relieved of the stress, it eventually returns to its original dimension. Elastic deformation is therefore a reversible and linear deformation. (MATERIALS STRENGH is a course to study the metal behavior in elastic stage)

1 Introduction
Metal forming* - a metal working process in which the shape of a work piece is altered to the required shape by plastic deformation without material removal. Second forming Plasticity* the materials ability of being permanently shaped or formed without fracture. The study of this course is to find answers to the following questions:
1) What metal forming technology can do for us ? 2) Why metals can be plastically deformed, and how the deformation affects the properties? (Physical metallurgy) 3) How metals deform under applied load or how load is applied to obtain a required shape? (Theory of plasticity,

This course = Physical metallurgy + Theory of plasticity

Mechanics)

1 Introduction
The interaction between the tool and the metal during plastic deformation expressed by a mathematic relationship is the field in Mechanics. Shape prediction-Computer Science

The relationship between the process and the metal properties Metallurgy.

The effect of the process on the microstructure and further the mechanical properties of metal.

1 Introduction
1.2 Outlines of the course
1) Stress analysis 2) Strain analysis 3) Yield criteria 4) Stress-strain relation and work hardening 5) Plastic anisotropy

6) Strain rate & temperature


7) Sheet metal forming

8) Application of simplified analytical methods to practical metal forming processes


9) Microstructure and plasticity

1 Introduction
1. 3 Major advantages of plastically forming process 1) Mechanical properties of the material improved 2) High productivity 3) High material utilization ratio 1.4 Characteristics of the subject 1) Mathematical theories are phenomenological in nature 2) Based on simplified approach: suggestive criteria, conditions and formulas. 3) Approximate solution

1 Introduction
1.5 Typical metal forming processes
1.5.1 Bulk forming
1) Free forging 2) Die forging 3) Rolling 4) Extrusion

5) Drawing 6) Rotary forging

1 Introduction
1.5.2 Sheet metal forming 1) Bending

2) Bulging
3) Stamping 4) Deep drawing 5) Blanking 6) Piercing

7) Spinning
8) Ironing 9) Other special forming processes

Manufacture process of a can

Al coil coil Blanking/cupping ironing trimming washing

coating

drying

printing

varnish coating

drying

Internal coating drying Necking in drying

Can cover manufacture process

coil

blanking/forming

curling

lining

end forming

tab forming

joining

Easy open lid

1 Introduction
References 1) Hosford WF, Caddell RM: Metal Forming Mechanics and Metallurgy, 3th edition, 2007, Cambridge University Press. 2) Ed. by L.Lippmann et al: Metal forming plasticity : Symposium Tutzing Germany, Aug 28-Sep 3,1978, Berlin, Springer 3) Avitzur, Betzalel: Metal forming; processes and analysis: 1968, McGraw-Hill, New York 4)

1 Introduction
Basis of the course 1) Elasticity Mechanics 2) Engineering Materials 3) Metal Forming Technology

1 Introduction
Homework
1) write a short paragraph on the content of this subject. Hand in your homework on the next class.

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