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Lecture 8

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Md Arman
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MLL371

Materials Processing (2-0-2)

Lecture # 8: Metal working

Department of Materials Science and Engineering, Indian Institute of Technology, Delhi

August 13th 2024


Recap
❑ Bulk and local deformation processes

❑ Nature of stresses involved in the them

❑ Concept of homologous temperature

❑ Dislocation involvement in plastic deformation and work hardening

❑ Difference between hot, cold and warm working

❑ Influence of hot and cold working on properties and grain structure of material.
Cold working
• Plastic deformation of metals much below the recrystallization
temperature (<0.3Tm) is known as cold working. It is generally
performed at room temperature. In some cases, slightly elevated
temperatures may be used to provide increased ductility and
reduced strength
• No heating is required
• Better surface finish is obtained
• Better dimensional control is achieved; therefore no secondary machining
is generally needed (These operations are near net shape or net shape
processes)
• Products possesses better reproducibility and interchangeability
• Better strength, fatigue, and wear properties of material
• Directional properties can be imparted
• Contamination problems are almost negligible
Cold working
• Disadvantages:
• Higher forces are required for deformation
• Heavier and more powerful equipment is required
• Less ductility is available
• Metal surfaces must be clean and scale-free
• Undesirable residual stresses may be produced
• Strain hardening occurs ( may require intermediate annealing or in some
cases material is not ductile enough to be processed )

• Cold forming processes, in general, are better suited for large-scale


production of parts which require small deformation, because of the cost of
the required equipment and tooling
Hot working
• High temperature decreases the flow stress, it can be utilized to decrease the
force and energy spent on deforming
• Hot Working is defined as deformation process at temperatures above the
recrystallzation temperature (>0.5Tm), where new and recrystallized grains
form during deformation
• The old grain structure deformed by previously carried out mechanical working
no longer exist, instead new crystals which are strain-free are formed which
give better mechanical properties to the finished parts
• In hot working, the temperature at which the working is completed is critical
since any extra heat left in the material after working will promote grain
growth, leading to poor mechanical properties of material
Hot working
• In comparison with cold working, the advantages of hot working are:
• No strain hardening
• Lesser forces are required for deformation
• Far greater ductility of material is available, and therefore more
deformation is possible.
• Favorable grain size is obtained leading to better mechanical properties of
material (low residual stress and high ductility)
• Equipment of lesser power is needed
• Work part shape can be substantially altered
• Not-so-ductile materials can also be deformed (eg. Mg-alloys)
• Strength properties are isotropic
Hot working
• Some drawbacks of Hot Working:

• A lot of energy is consumed in heating


• Lubrication is more difficult
• Oxidation and increased reactivity of the work metal
• Reduced tool life because of increased wear-rate at high temp
• Lack of dimensional control of the finished component, because of the
thermal expansion
• Poor surface finish
• Lack of work-hardening is undesirable where the strength level of a cold-
worked product is needed
Warm working
• Metal deformation carried out at temperatures intermediate to hot and cold
forming is called Warm Forming or Working . Usually the temperature is above
0.3Tm and below recrystallization temperature (~0.5Tm). Compared to cold
forming, warm working offers several advantages. These include:

• Lesser loads on tooling and equipment


• More intricate geometries possible
• Greater metal ductility
• Fewer number of annealing operation ( because of less strain hardening )
Warm working
• Compared to hot forming, warm forming offers the following
advantages
• Lesser amount of heat energy requirement
• Better precision of components
• Lesser scaling on parts
• Better dimensional control
• Better surface finish
• Lesser thermal shock on tooling
• Lesser thermal fatigue to tooling, and so greater life of tooling
Concept of flow stress and flow curve
• For most metals at room temperature,
strength increases when deformed due to
strain hardening
• Flow stress = instantaneous value of
stress required to continue deforming the
material

Also known as power law


Flow behavior

What is flow curve?

Plot of change in yield stress with plastic strain is called “Flow curve”

It gives stress required to make material flow plastically

There are several parameters which are important to look at when


materials is undergoing plastic deformation. There are stress, strain,
strain rate and temperature.
Strain rate

Do you know what kind of strain rates are involved in


common metal working processes or tensile test?
Strain rate
• Rate of straining is directly related to speed of deformation v
• Deformation speed v = velocity of the ram or other movement of the
equipment

Strain rate is defined:


. v
 =
. h

where = true strain rate; and h = instantaneous height of workpiece
being deformed

• Values can range from 10-3 to 100 s-1

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