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Lecture - 1 - Flow Curve and Hardening

The document outlines the syllabus and grading criteria for a course on Metal Forming, taught by Dr.-Ing. Nader Nabil Zaafarani. It covers topics such as the definition and classification of metal forming processes, stress-strain curves, and strain hardening, along with references for further reading. The course emphasizes the importance of understanding both mechanical and metallurgical aspects of plasticity in metal forming applications.

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mr.767.r
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2 views24 pages

Lecture - 1 - Flow Curve and Hardening

The document outlines the syllabus and grading criteria for a course on Metal Forming, taught by Dr.-Ing. Nader Nabil Zaafarani. It covers topics such as the definition and classification of metal forming processes, stress-strain curves, and strain hardening, along with references for further reading. The course emphasizes the importance of understanding both mechanical and metallurgical aspects of plasticity in metal forming applications.

Uploaded by

mr.767.r
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Theory of Metal ‫نظرية تشكيل‬

Forming ‫المعادن‬

Instructor : Grading :
Total Grade : 150
Dr.-Ing. Nader Nabil Zaafarani Final Exam : 100
Term Work : 50
Teaching Assistant : (Midterm Exam’s, Assignments,
Reports, Sketch, Attendance)
Eng. Mohamed AlNaggar
Notes :
(a) Important: ‫اإللتزام بمواعيد المحاضرات و حصص التمارين‬

(b) Make a good review on the courses Strength and Materials Testing
and Stress Analysis

References :

Metal Forming (Mechanics and Metallurgy) W.S.Hosford


R.M.Caddell

Mechanics of Sheet Metal Forming Z. Marciniak,


J.L.Duncan, S.J. Hu

Metal Forming Handbook Schuler Co.

Handbook of Die Design I. Suchy

Theory of Plasticity J. Chakrabarty


Syllabus:

• Review on Stress-strain Curve


• Basic study of plasticity
von-Mises
Tresca yield functions
• Hot forming and cold forming
• Methods of solving problems
Ideal work
Strip method or force equilibrium
FEM
Syllabus:

• Friction and tribology in metal forming


• Effect of temperature and strain rate on
stress and strain
• Mechanical and metallurgical aspects in plasticity
•Applications of forming theory
Rolling (analytical and theoretical study)
Extrusion
Wire drawing
Deep Drawing
Spring-back
1- Introduction:

1-1 Definition of Metal Forming:

Metal Forming is a process by which the


shape of a metallic workpiece is changed
without removal or addition of any excess
metal.
1-2 Classification of Metal Forming Processes:

(1) According to Temperature:

Cold Forming Hot Forming

- Deep Drawing -Forging


- Wire Drawing -Rolling of sections
- Cold Forging -Hot extrusion
- Bending
-Spinning
-Thread Rolling
(2) According to variation of stresses and
strains with respect to time:

Steady Process Non-steady Process


(3) According to The type of workpiece:

Sheet Metal Forming Bulk Metal Forming

- For production of - For production of


shells, containers, massive workpiece
tubes … etc. - Forging
- Deep Drawing - Wire Drawing
- Bending - Extrusion
2- Flow curve:
2-1 The Tension Test:

engineering - stress engineering - strain


where E (GPa or psi) is the modulus of elasticity, or Young’s modulus
2-2 The true stress- true strain curve:
The plastic part of the true stress true strain
curve (flow-curve) determines the stress level
( sf) required to cause plastic deformation of
the metal at a given strain (j).
Definition of true strain (j) :

As the engineering strain is defined by de =

And hence the total value of the engineering strain is


l
dl
calculated by e = 
l
l0 0

The true strain is defined by dj =


And hence the total value of the engineering strain is
l
dl l 
calculated by j =  l = ln  l 
l0  0

j is also called logarithmic strain or natural strain


Relation between engineering strain (e) and
true strain (j) :

Before necking occurs j = ln(1 + e).

After necking the true strain must be based on


the area:

dj = − dA/A or j = ln(A0/A).
Example 2.1:
A bar is to stretched from initial length l0 to a final
length of 2l0. Get the values of the engineering and
true strains in that operation.
Upon compression to the initial length compute
both strains.
Comment on the results.
Example 2.2:
A bar of 100 mm initial length is elongated to a length of 200 mm by
drawing in three stages. The length after each stage is :
120 mm ; 150 mm and 200 mm.
a) Calculate the engineering strain for each stage separately and
compare the sum with the total overall value of e.
b) Repeat (a) for the true strain j and comment on the results.

Solution:
Definition of true stress (s ):
F
sf =
A

Relation between engineering


stress (s) and true stress (s ) :
The true stress sf = F/A can be found before
necking as:

s = s (A0 / A) or s = s (1 + e )
2-3 Strain Hardening in Simple Tension :
The requirement to apply higher stresses in order to
induce further plastic deformation is due to a
material property called “ strain hardening ”.
It may be expressed as :
s = Y = F (  dj )
where F is the strain hardening
function and may be experimentally
defined by fitting a suitable
empirical relation
Empirical Relations for Stress-Strain curves:

elastic part : s = E ee Hook’s law


plastic part : s = K jn Power law

“K” and “n” are material constants


“n” is called strain-hardening exponent

K (MPa) n
Annealed low carbon steel 760 0.19
Annealed copper 315 0.54
Aluminum, 1100 180 0.2
Generalized power-law (Swift):

s = K ( j 0 + j )n

“j0” is initial strain (pre-strain) in the


material
Idealized Stress-Strain curves:

a) elastic strain-hardening b) rigid strain-hardening c) elastic perfectly-plastic

e) elastic linear strain-hardening


d) rigid perfectly-plastic
2-4 Determination of the Flow-curve from Tension Test:
F (kg) or (N) or (lb)
d (mm) or (in)
s (MPa) or (psi )
e (mm/mm) or (in/in)
sf (MPa) or (psi)
j (mm/mm) or (in/in)
As the gauge length (L0) and the original cross-section
(A0) are known the following can be calculated:

s = s (1 + e )

j = ln(1 + e)
The values of K and n in the power law can be
found by plotting the true stress–strain curve on
log–log coordinates.

Noting that from σ = K j n and taking the logarithm


of both sides:
log σ = log K + n log j

y=b+ax

so the slope equals n and K is the intercept at j = 1

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