ASSIGNMENT 2 (Group report)

KIG4027 (Sem 2, 2020/21)

Question #01 (b)
1 Introduction
Bulk deformation processes are performed as cold, warm, and hot working operations. Cold and
warm working is appropriate when the shape changes less severe, and there is a need to improve
mechanical properties and achieve good finish on the part. Hot working is generally required
when massive deformation of large work parts is involved.

2 Types of Bulk deformation Processes

There are four main types of bulk deformation processes which are further divided into different
sub types.
1. Rolling
a. According to Geometry
i. Flat Rolling
ii. Shape Rolling
b. According Temperature of work
i. Hot Rolling
ii. Cold Rolling
2. Forging
a. Open Die Forging
b. Impression Die Forging
c. Fleshless Forging
3. Extrusion
a. According to Geometry
i. Direct Extrusion or Forward Extrusion
ii. Indirect Extrusion or Backward Extrusion or Reverse Extrusion
b. According Temperature of work
i. Cold Extrusion
ii. Hot Extrusion
c. According to Nature of Product
i. Continuous Extrusion
ii. Discrete Extrusion
4. Drawing
a. Wire Drawing
b. Bar Drawing
2.1 Rolling
Rolling is a deformation process in which the thickness of the work is reduced by compressive
forces exerted by two opposing rolls. The rolls rotate to pull and simultaneously squeeze the
work between them.
2.1.1 Flat Rolling
Flat rolling used to reduce thickness of a rectangular cross section. It involves the rolling of
slabs, strips, sheets, and plates work parts of rectangular cross section in which the width is
greater than the thickness. In flat rolling, the work is squeezed between two rolls so that its
thickness is reduced by an amount called the draft.

2.1.2 Shape Rolling

In shape rolling, the work is deformed into a contoured cross section. Products made by shape
rolling include construction shapes such as I-beams, L-beams, and U-channels rails for railroad
tracks and round and square bars and rods. The process is accomplished by passing the work
through rolls that have the reverse of the desired shape.
2.1.3 Hot Rolling
Most rolling is carried out by hot working, called hot rolling, owing to the large amount of
deformation required. Hot-rolled metal is generally free of residual stresses, and its properties are
isotropic.

2.1.4 Cold Rolling

Further flattening of hot-rolled plates and sheets is often accomplished by cold rolling, in order
to prepare them for subsequent sheet metal operations. Cold rolling strengthens the metal and
permits a tighter tolerance on thickness. In addition, the surface of the cold-rolled sheet is absent
of scale and generally superior to the corresponding hot-rolled product.
2.2 Forging
Forging is a deformation process in which the work is compressed between two dies, using either
impact or gradual pressure to form the part. It is the oldest of the metal forming operations,
dating back to perhaps 5000 BCE. Today, forging is an important industrial process used to
make a variety of high-strength components for automotive, aerospace, and other applications.
These components include engine crankshafts and connecting rods, gears, aircraft structural
components, and jet engine turbine parts.

2.2.1 Open Die Forging

The simplest case of open-die forging involves compression of a work part of cylindrical cross
section between two flat dies, much in the manner of a compression test. This forging operation,
known as upsetting or upset forging, reduces the height of the work and increases its diameter.
2.2.2 Impression Die Forging
Impression-die forging, sometimes called closed-die forging, is performed with dies that contain
the inverse of the desired shape of the part. The raw work piece is a cylindrical part similar to
that used in the previous open-die operation. As the die closes to its final position, flash is
formed by metal that flows beyond the die cavity and into the small gap between the die plates.

2.2.3 Fleshless Forging

As mentioned above, impression-die forging is sometimes called closed-die forging in industry
terminology. However, there is a technical distinction between impression-die forging and true
closed-die forging. The distinction is that in closed-die forging, the raw work piece is completely
contained within the die cavity during compression, and no flash is formed. The term fleshless
forging is appropriate to identify this process.

2.3 Extrusion
Extrusion is a compression process in which the work metal is forced to flow through a die
opening to produce a desired cross-sectional shape. The process can be likened to squeezing
toothpaste out of a toothpaste tube. Extrusion dates from around 1800.
2.3.1 Direct Extrusion or Forward Extrusion
A metal billet is loaded into a container, and a ram compresses the material, forcing it to flow
through one or more openings in a die at the opposite end of the container. As the ram
approaches the die, a small portion of the billet remains that cannot be forced through the die
opening. This extra portion, called the butt, is separated from the product by cutting it just
beyond the exit of the die.

2.3.2 Indirect Extrusion or Backward Extrusion or Reverse Extrusion

In indirect extrusion, also called backward extrusion and reverse extrusion, the die is mounted to
the ram rather than at the opposite end of the container. As the ram penetrates into the work, the
metal is forced to flow through the clearance in a direction opposite to the motion of the ram.
Since the billet is not forced to move relative to the container, there is no friction at the container
walls, and the ram force is therefore lower than in direct extrusion.
2.3.3 Cold Extrusion
Cold extrusion doesn’t involves prior heating of the billet to a temperature above its
recrystallization temperature. Extrusion can be performed either hot or cold, depending on work
metal and amount of strain to which it is subjected during deformation. Metals that are typically
extruded hot include aluminum, copper, magnesium, zinc, tin, and their alloys. These same
metals are sometimes extruded cold. Steel alloys are usually extruded hot, although the softer,
more ductile grades are sometimes cold extruded (e.g., low carbon steels and stainless steel).
Aluminum is probably the most ideal metal for extrusion (hot and cold), and many commercial
aluminum products are made by this process (structural shapes, door and window frames, etc.).
2.3.4 Hot Extrusion
Hot extrusion involves prior heating of the billet to a temperature above its recrystallization
temperature. This reduces strength and increases ductility of the metal, permitting more extreme
size reductions and more complex shapes to be achieved in the process.
2.3.5 Continuous Extrusion
A true continuous process operates in steady state mode for an indefinite period of time. Some
extrusion operations approach this ideal by producing very long sections in one cycle, but these
operations are ultimately limited by the size of the starting billet that can be loaded into the
extrusion container. These processes are more accurately described as semi-continuous
operations. In nearly all cases, the long section is cut into smaller lengths in a subsequent sawing
or shearing operation.
2.3.6 Discrete Extrusion
In a discrete extrusion operation, a single part is produced in each extrusion cycle. Impact
extrusion is an example of the discrete processing case.

2.4 Drawing
Drawing is an operation in which the cross section of a bar, rod, or wire is reduced by pulling it
through a die opening. The general features of the process are similar to those of extrusion. The
difference is that the work is pulled through the die in drawing, whereas it is pushed through the
die in extrusion
2.4.1 Wire Drawing
Wire drawing is a metalworking process used to reduce the cross-section of a wire by pulling the
wire through a single, or series of, drawing die.
2.4.2 Bar Drawing
Bar drawing is a metalworking process which uses tensile forces to stretch metal, glass, or
plastic. As the metal is drawn (pulled), it stretches thinner, into a desired shape and thickness.

Question #01 (c)

3 Simulations Conditions and the Software Used
Following software’s can be used for simulation of bulk deformation.
 DEFORM-2D
 EDEM
 ANSYS
 MATLAB

3.1 DEFORM-2D
DEFORM-2D software package (V7.2) will be used for numerical simulation. Bulk metal
forming in open die process implies a lot of problems both from the point of view of geomtry
and technological condition.

3.2 Conditions
 Material is an aluminum alloy AlMgSi0,5.
 Investigation is carried out at hot forming temperature of T=440 [o C]
 Deformation is obtained by a small constant deformation velocity of v=2 [mm/s]
 Strain hardening curve parameters are
 c=30.34434
 n=0.097808 for AlMgSi0.5 aluminum alloy
 Temperature T=440 [o C]
 Friction factor is m=0.114