IE370Lecture15 - 15.1 Introduction Chapter 15: Fundamentals...

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1 Chapter 15: Fundamentals of Metal Forming 15.1 Introduction s Deformation processes have been designed to exploit the plasticity of engineering materials s Plasticity is the ability of a material to _______ without deterioration of properties s Deformation processes require a large amount of force s Processes include bulk flow, simple shearing, or compound bending States of Stress 15.2 Forming Processes: Independent Variables s Forming processes consist of _________ and __________variables s Independent variables are the aspects of the processes that the engineer or operator has direct control b Starting material b Starting geometry of the workpiece b Tool or die geometry b Lubrication b Starting temperature b Speed of operation b Amount of deformation
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2 Forming Operations Forming Operations Forming Operations 15.3 Dependent Variables s Dependent variables are those that are determined by the ________ variable selection b Force or power requirements b Material properties of the product b Exit or final temperature b Surface finish and precision b Nature of the material flow
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3 15.4 Independent-Dependent Relationships s Independent variables- control is direct and immediate s Dependent variables- control is entirely indirect b Determined by the process b If a dependent variable needs to be controlled, the designer must select the proper independent variable that changes the dependent variable Independent-Dependent Relationships s Information on the interdependence of independent and dependent variables can be learned in three ways b Experience b Experiment b Process modeling Figure 15-1 Schematic representation of a metalforming system showing independent variables, dependent variables, and the various means of linking the two. 15.5 Process Modeling s Simulations are created using finite element modeling s Models can predict how a material will respond to a rolling process, fill a forging die, flow through an extrusion die, or solidify in a casting s Heat treatments can be simulation s Costly trial and error development cycles can be eliminated 15.6 General Parameters s Material being deformed must be characterized b Strength or resistance for deformation b Conditions at different temperatures b Formability limits b Reaction to lubricants s Speed of deformation and its effects s Speed-sensitive materials- more energy is required to produce the same results
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4 Stresses in Metal Forming s Stresses to plastically deform the metal are usually compressive b Examples: rolling, forging, extrusion s However, some forming processes b Stretch the metal ( tensile stresses) b Others bend the metal ( tensile and compressive) b Still others apply shear stresses Material Properties in Metal Forming s Desirable material properties: b Low yield strength and high ductility s These properties are affected by temperature : b Ductility increases and yield strength decreases when work temperature is raised s Other factors: b Strain rate and friction Bulk Deformation Processes
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This note was uploaded on 09/23/2009 for the course IE 370 taught by Professor Chunghorng,r during the Spring '08 term at Purdue University-West Lafayette.

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IE370Lecture15 - 15.1 Introduction Chapter 15: Fundamentals...

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