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    Forging Analysis 1604163281642

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    Abhidraw
    The document discusses friction in cold and hot metal working processes. In cold working under lubricated conditions, there is sliding friction between the tool and workpiece described by Coulomb's law. In hot working, sticking friction is more common where the workpiece surface sticks to the tool. The analysis considers the workpiece interface has a constant shear strength related to the material's yield strength.

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    Forging Analysis 1604163281642

    Uploaded by

    Abhidraw
    35 views24 pages
    The document discusses friction in cold and hot metal working processes. In cold working under lubricated conditions, there is sliding friction between the tool and workpiece described by Coulomb's law. In hot working, sticking friction is more common where the workpiece surface sticks to the tool. The analysis considers the workpiece interface has a constant shear strength related to the material's yield strength.

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    Forging_Analysis_1604163281642

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    The document discusses friction in cold and hot metal working processes. In cold working under lubricated conditions, there is sliding friction between the tool and workpiece described by Coulomb's law. In hot working, sticking friction is more common where the workpiece surface sticks to the tool. The analysis considers the workpiece interface has a constant shear strength related to the material's yield strength.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    35 views24 pages

    Forging Analysis 1604163281642

    Uploaded by

    Abhidraw
    The document discusses friction in cold and hot metal working processes. In cold working under lubricated conditions, there is sliding friction between the tool and workpiece described by Coulomb's law. In hot working, sticking friction is more common where the workpiece surface sticks to the tool. The analysis considers the workpiece interface has a constant shear strength related to the material's yield strength.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 24

     Let us assume that length (l) is much larger than


    width and thickness and it remains constant.
     So, it is a case of plane-strain deformation.
     Lateral flow of material causes increase in width.
     Let us assume the width has increased to ‘2a’.
     To estimate load required (P) in forging to reduce
    the thickness of the plate to a thickness ‘h’.
    1
     The Von-Mises yield criterion for plane strain
    condition is

    Substituting in equation (1)

    2
    Friction in cold working
    • In cold working under well lubricated
    conditions, the frictional conditions at the
    tool-work piece interface are such that there
    is a sliding motion between the two. The
    work piece slides over the tool surface.
    • It is called sliding friction or slipping
    friction.
    Friction in cold working
    • If sliding friction conditions exist, friction is
    described by Coulomb’s law of friction:
    τ = μp
    where τ is frictional shear stress at the
    interface
    p is normal stress and
    μ is coefficient of friction (0.1-0.3)
     Case (1): Sliding friction:
    From Coulomb’s law of friction,

     So, equation (2) becomes


    3
     Integrating equation (3) both sides
    4

     Constant of integration can be found out by the


    boundary condition

     At , ,
     So,

     Substituting in equation (4)


    5

     The pressure increases exponentially as we


    move from edge to the centre of the plate and
    builds up to a maximum at the centre.
     This is called friction hill.
     Centreline is neutral surface.
     At centre,

     So, peak pressure

     At the edge, , So,

     At any point

     At centre,
     At the edges,
    6
     Where

     Forging load,
    Friction in hot working
    • An alternative approach to treat friction in metal
    working operations is to consider the friction to be
    “sticking”.
    • Sticking friction conditions exist particularly in
    hot working processes and in those situations
    where lubrication is inadequate.
    • This approach considers that the work piece in
    contact with the tools can be represented as a
    material of constant shear strength.
    Friction in hot working
    • This interface shear strength can be expressed as a
    fraction of yield strength of the material in pure
    shear (k):
    τ=mk
    where m is the interface friction factor.
    Values of m vary from 0 to 1.
    m = 0 indicates perfect sliding.
    m = 1 indicates prefect sticking.
    Since accurate determination of m value in hot
    working is difficult, m is taken to be 1 in the
    analysis.
     Case (2): sticking friction

    Where “m” is the interface friction factor and

    k is YS in pure shear.

    according to Von-Mises yield criterion

     In this case equation (2) becomes


     Integrating on both sides
    7

     Applying the boundary condition,


     At , ,
     Substituting in equation (7),

    8
     Mean forging pressure,

     Forging load,

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