GIÁO TRÌNH KHAI THÁC PHẦN mềm TRONG GIA CÔNG KHUÔN mẫu chapter i introduction

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GIÁO TRÌNH KHAI THÁC PHẦN mềm TRONG GIA CÔNG KHUÔN mẫu chapter i introduction

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THEORY OF PLASTICITY and ITS APPLICATIONS INSTITUTE OF METAL FORMING This Script has been given for Master Course “Mold and Die Engineering” in KUAS Content Chapter I: Introduction Chapter II: Metallurgical Fundamentals Chapter III: Strain Chapter IV: Stress Chapter V: Yield Criteria Chapter VI: Flow Rule Chapter VII: Flow Curve Chapter VII: Analysis Methods Extra Chapt FEM Simulation Chapter IX: Bulk Forming Processes Chapter X: Sheet Forming Processes TOTAL LECTURE PERIOD: W Chapter I: Introduction Content • • • • • • Classification of Manufacturing Processes Advantages of Metalforming Processes Classification of Metalforming Processes Examples of Metalforming Processes Metalforming Machines Metal Forming System Chapter I: Introduction Questions about production… CV Joint Crankshaft Rear part of TOYOTA Manufacturing Processes Manufacturing processes produce solid bodies with given geometry and given properties Creation of Cohesion Maintenance of Cohesion Destruction of Cohesion Increase of Cohesion Shape (Form) Modification Primary Forming (Form generation) Deforming Separating Joining Coating Changing Material Properties Rearrangement of Particles Removal of Particles Addition of Particles Maintenance of Cohesion: Duy trì s liên k t Chapter I: Introduction Manufacturing Processes Primary Forming: Casting, Powder Metallurgy Deforming: Metal Forming Processes (Bulk and Sheet Forming) Separating: Machining (with Cutting Tool or with Abrasive Tool), Non-Traditional Machining (Laser) Joining: Welding, Joining Coating: Various Changing Material Properties: Heat Treatments (temper, blank a fire) Chapter I: Introduction Manufacturing Processes Casting of Stator made of gray iron Milling on Milling-machine with axes Drilling Lathe Manufacturing Processes Jioning with rivet Welding Coating of TiN by method PVD Thremal treatment Manufacturing Processes Drawing of car body parts Parts of machines Car body parts Hollow parts used in conduit of oil or gas Basic Question of Manufacturing How can we manufacture a technical product with given specific dimensional and shape tolerances, given surface structure and given material properties most economically? Weld Primary Forming: Casting Metal Forming Example Step-shaft ? Separation: Turning Waste Chapter I: Introduction Joining: Welding 10 Comparision of Machining and Metalforming • Forces and stresses in metalforming are high – Metalforming: stresses between 50 to 2500 MPa, forming forces are upto 75,000 tons – Metal cutting: Forces about to 20 tons • Tools are large, heavy and expensive • Minimum workpiece quantities are necessary Chapter I: Introduction 11 Advantages of Metalforming • High material utilization [,ju:təlai'zei∫n] t n d ng (no waste, shavings by manufacturing) • High productivity with short production times • High dimensional and shape accuracy within certain tolerances • Superior [su:'piəriə] t t mechanical material properties of the product (especially for dynamic loadings) Chapter I: Introduction 12 Grain Flow Comparison (a) casting, (b) machining, (c) forging Fiber/Structure of a Drive Shaft after the Extrusion 13 Definition of Metal Forming Metalforming bases on plastic deformation of metal Metalforming is the manufacturing by plastic (permanent) change of the form of a solid body by preserving (duy trì) both the mass and the cohesion Chapter I: Introduction 14 Classification Metal Forming Processes Metalforming Compressive Forming Combined Tensile and Compressive Forming Tensile Forming Forming by Bending Forming by Shear Rolling Pulling through a Die Stretching B w Linear Tool Motion Joggling Open-Die Forming Deep Drawing Expanding B w Rotary Tool Motion Twisting Closed-Die Forming Spinning Recessing Indenting Flange Forming Pushing through a Die Upset Bulging By the primary stress in the deformation zone Further classification by kinematics, tool geometry and workpiece geometry leading to more than 200 basic processes! Chapter I: Introduction 15 Classification Metal Forming Processes Metal Forming Processes Bulk Forming Processes • Spatial workpieces • Large changes in cross-section & large changes in thicknesses • Material flows in all directions • Generally multi-axial compressive stress states • Larger relative forces Sheet Forming Processes • Planar workpieces (sheets, plates) • Hollow pieces with almost constant wall thickness • Generally two-axial stress states: tensile-tensile/tensile-compressive Chapter I: Introduction 16 Classification Metal Forming Processes Bulk Forming Processes Steady-State Processes Non-Steady-State Processes Deformation patterns are independent of time Deformation patterns are dependent of time Examples: Extrusion, rolling, drawing Examples: Upsetting, forging, extrusion Chapter I: Introduction 17 Classification Metal Forming Processes Metal Forming Processes Cold Forming Warm Forming Hot Forming Forming at room temperature (everyday sense) Forming above room temperature (everyday sense) Forming below the recrystallization temperature Forming below or around Forming above the recrythe recrystallization stallization temperature temperature Steel: Room Temperature Steel: 750-950oC Forming above room temperature (everyday sense) Steel: 1150-1250oC Chapter I: Introduction 18 Recyrstallization Temperatures Material Recrystallization Temperature Material Recrystallization Temperature C-Steel 550oC tin to 40oC Pure-Al 290 to 300oC zinc 50 to 100oC Dur-Al 360 to 400oC Mo 870oC W 900-1000oC Ni 400-600oC Cu Lead (chì) 200oC (changes drastically with alloying elements) -50 to 50oC Recrystallization temperatures depend on prior plastic strain Chapter I: Introduction 19 Notice temperature by forming process!!! Temperatures • • • • • • • • Room temperature Initial temperature of workpiece before forming Average temperature of workpiece after forming Surface temperature of workpiece after forming Highest temperature of workpiece during forming Average temperature of tools Highest temperature of tool-interface during forming Initial temperature of tool Chapter I: Introduction 20 10 Examples of Metalforming Processes: Compressive Forming Flow Turning, Spinning: Chapter I: Introduction 33 Design a model of spinning machine to producing of bottles for high pressure gas Chapter I: Introduction 34 17 35 Examples of Metalforming Processes: Combined Tensile & Compressive Forming Spinning: Orbit motion of Spinning roller Disc Blank Spinning Roller Mandrel Clamping Plate Trimming Plate Spindle Cross Slide Tailstock Chapter I: Introduction Blank Support Unit 36 18 Examples of Metalforming Processes: Combined Tensile & Compressive Forming Spinning: Axis-symmetric Parts Chapter I: Introduction See some movies ! 37 Examples of Metalforming Processes: Combined Tensile & Compressive Forming Wire Drawing: d0 z d1 d0 r Ftotal α Chapter I: Introduction 38 19 Examples of Metalforming Processes: Combined Tensile & Compressive Forming Deep drawing: Wash basin Chapter I: Introduction 39 Products by deep drawing 40 20 Examples of Metalforming Processes: Combined Tensile & Compressive Forming Deep drawing: Courtesy of University of Munich Chapter I: Introduction 41 Examples of Metalforming Processes: Combined Tensile & Compressive Forming Deep drawing examples (Sidepanel – ULSAB) Chapter I: Introduction Courtesy Niels Bay 42 21 Examples of Metalforming Processes: Combined Tensile & Compressive Forming Deep drawing examples Products: pot, pan, basin Courtesy Niels Bay Chapter I: Introduction 43 Examples of Metalforming Processes: Combined Tensile & Compressive Forming Flange Forming: Chapter I: Introduction 44 22 Examples of Metalforming Processes: Combined Tensile & Compressive Forming Hydroforming: Closing of the press Filling the water Courtesy of Schuler Pressurizing/compressing Opening the press Chapter I: Introduction 45 Examples of Metalforming Processes: Combined Tensile & Compressive Forming Cap for pump housing (IPL, Grundfos) Hydroforming Examples Camera housing Parabolas (IPL) Courtesy Niels Bay Chapter I: Introduction 46 23 Examples of Metalforming Processes: Combined Tensile & Compressive Forming Hydroforming Examples Courtesy Niels Bay Chapter I: Introduction 47 Examples of Metalforming Processes: Tensile Forming Stretch-forming: Chapter I: Introduction 48 24 Metalforming Machines Forming Machines Linear Relative Motion of the Tools Rolling Machines Drawing Machines Nonlinear Relative Motion of the Tools Presses Rolling Machines Energy Driven Forming Medium Forming Energy Lateral Displacement Driven Stretching Machines Longitudinal Force Driven Bending Machines Special Machines Oblique by K Lange Chapter I: Introduction 49 Metalforming Machines: Examples (1) Compressed air hammer Hydraulich hammer 50 25 Metalforming Machines: Examples (1) Crank press machine Hydraulic press machine Chapter I: Introduction 51 Crank press machine 52 26 Hydraulic press machine 53 Hydraulic press machine (transfer press) 54 27 Metalforming Machines: Examples (2) Hydraulic Press Mechanical Press Courtesy Eres Söylemez Chapter I: Introduction 55 Metalforming Machines: Examples (3) Hydraulic Press Mechanical Press Courtesy Eres Sưylemez Chapter I: Introduction 56 28 D©y chun s¶n xt trơc khủu 57 Roller for Sheet Rolling mill 58 29 Rolling mill 59 Rolling 60 30 Metalforming System System items: Deformation zone Properties before deformation Properties after deformation Workpiece-tool interface Tools Surface reactions Machine tool (presses) Factory by Backofen, Gebhardt, Kienzle, Lange, Schey Chapter I: Introduction 61 31 ... Compressive Forming Impression Die Forging: Upsetting: Chapter I: Introduction 22 11 Examples of Metalforming Processes: Compressive Forming Open die forging: Chapter I: Introduction 23 Impression Die... Non-Traditional Machining (Laser) Joining: Welding, Joining Coating: Various Changing Material Properties: Heat Treatments (temper, blank a fire) Chapter I: Introduction Manufacturing Processes Casting... Metalforming Processes: Compressive Forming Ring Rolling Chapter I: Introduction 32 16 Examples of Metalforming Processes: Compressive Forming Flow Turning, Spinning: Chapter I: Introduction 33 Design

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