Page 188

Equationo ofFlowCurvve
Ana
alysis
s of Forg
ging (a)Withsttrainhardening
   Vo K(T )n 
  e.g. Vo 0 (T )0.3
1000

True stress and Trrue Strrain Here ı o iss flow stresss but it is truee stress and İ T is truestraain. 
Th
he true strress is defiined as thee ratio of th
he load to the cross section are
ea at any (b)Withou
utstrainhard
dening:
lload    V o V y  
nstant. TT
in  T 1 F
Instanta
aneous area
a

W
Where T annd F is thee engineering stress and
a engineeering strain
n respective
ely.

Trrue strain

L
Elongation
E dxx L¬ A ¬ d ¬
FT  ¨  ln žžž ­­­  ln 1 F  ln žž o ­­­  2 ln žž o ­­­
Instan
ntaneouslennght L x žŸ Lo ®­ Ÿž A ® žŸ d ®
o

ng strain ( F ) = e FT -1
orr engineerin

The volume of the specimen

s iss assumed to
t be consta
ant during plastic defformation. 
[ ' Ao Lo  AL ] It is valid
v till th
he neck form
mation. 
Wewillannalyzeonlyoopendieforgingusingsllabmethodofanalysisffor
(1)RectanngularBarforging,and
Flow Stress
s (2)AxiͲsym
mmetricforgging
Whenam
materialdeformsplasticalllystrainharrdeningoccurs. 1. Rec
ctangu
ular Bar Forgiing
 
 Beforeforging  Afterfforging (lenggth n height p) 
B B

h
h1
2L
2L1 

x Here we are using plane

p strain n i.e. width won’t increease.
n condition
x At the en
nd of the forging,
f forrce will be maximum m because oof the area involved
between the die and
d the workp piece is ma
aximum.
x Geometry should bee taken at end
e of forgiing
P
dx

B Wx
x
Forgingoccursinplassticzonei.einbetween V y and Vult (Vx+d Vx)
h x
V y –YieldStress x =0
V o – For forging,
f we need flow stress
s and fllow stress iss not constaant and depends on stress of the 2L
L Wx
P
workpiecee.
Vult –Ultimmatetensilestresshereneckformationstarts. x 0 , is the point at
a which thhe material does not move
m in any
y direction.
 Take an element dxx at a distance of x (en
nlarged view
w):





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 Page 189

As 2 0 (' Plane stra

ain conditioon)
V2 QV1 QV3
  0
E E E
V2 Q( V1  V3 )
Fig. FBD
F of Elements orr V2 Q( Vx  P)
§ 1·
Now elem
ment will loook like a slab
s and hence its nam
me slab metthod of ana
alysis. Note: In theories off plasticity ¨ Poisson's ratio,ǎ
r = ¸ as volume change nott occur.
© 2¹
x On left sidee (stress x area) = Force V x u Bh and on other side force e will be
1
Therefore, V2 V P
V x  dV x Bh
B . 2 x
x Upper die will
U w give preessure on upper
u surface and lower surface will get pre
essure by From Vo
on-Mises theory:
t
2 
= P × area = (P × B× dx)
loower die. Soo on upper side force= d & similarly on low wer side = ­ 1 ½ ­1 ½ 2
®V x  ( V x  P) ¾  ® ( V x  P)  P ¾  (  P  V x ) 2V02
P B dx )
(P ¯ 2 ¿ ¯2 ¿
x As metal is moving ou utwards soo friction force
f will act
a in oppoosite directtion, this ( V x  P)2 ( V x  P)2
or   ( V x  P)2 2V20
frriction force is shear force and d will causse shear sttress on th
he surface equal to 4 4
(WWx B dx ) in lo
ower and upper
u surface. 3
or ( V x  P))2 2 V20
2
At the en
nd of forgin
ng the systeem must bee in equilibrrium; thereefore net reesultant forrce in any 4 2
or ( V x  P)2 V0
direction
n is zero. 3
? 6 Fx 0; Gives 2
or ( V x  P) V0
( Vx  d Vx ) B h  Vx . B h  2Wx . B dx 0 3
or d Vx B h  2Wx B dx 0 V0
or Vx  P 2 K ….(2)) [where K = flow shear strress]
or d Vx . h  2Wx dx 0 3
dV x 2W x resca’s th
From Tr heory :
 0 (1
1) V1  V3 V0
dx h
Here theere are thrree variablees Vx , Wx and x so we reduce
r it in
nto two va
ariables by applying or Vx  P V0
condition
n. V0
or   Vx  P 2 K ….(2)) [where K = flow
w shear strress]
2
For a ducctile materrial there arre two the
eories of plasticity.
Differenttiating equation (2)
1. Von-M ory: (V1  V2 )2  ( V2  V3 )2  ( V3  V1 )2
Mises Theo 2 V02

2. Tresca’s Theory
y: V1  V3 V0

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 Page 190

dV x d P 2P
 0 (L  x )
dx dxx
or P 2K . e h
.... (5) (Pressure
( d
distribution
n equation)
dVx d P
or ....(3) 2P
(L)
dx dxx At x = 0, Pmax K eh
2K
Condition-1: 2P
(0)
At x = L, Pmin K eh
2K 2K
dering sliding fric
Consid ction all over the
e surface ( Wx PP )

dx
PBd

W × Bdx

F = ǍN
N
or dF = ǍdN
Ǎ
Wx B dx P . PB dx
Wx PP
From equ
uation (1) and
a (3)
d V x 2W x
 0
dx h
d P 2P P Elementa
al force, dF
F = P.B.dx
or   0 2P
(L  x )
dx x h dF = 2K e h . B.dx
dP 2P
or ³ P  h ³ dxx L 2P
. (L  x ) § L L
·
Integratiing, F 2 u ³ (2 K . e h
. B . dx ) ¨¨' ³ gives half we use 2³ ¸¸
h portion F so for 2L w
2P 0 © 0 0 ¹
or ln P  x C ......(4) L 2P
h (L  x )
F 4 KB .³ e h . dx
0

Condition-2:
Consid
dering sticking frriction all over the surfac
ce ( Wx Wy K )
Shear faiilure will occur at each and everry point.

Boundary condition ns, at x = L, V x 0 (because

( no
o force is applied soo no stresss on that
surface) and Vx  P 2K gives P = 2 K
2P
or ln 2 K  LC
h
2P From equ
uation (1) and
a (3)
or C ln 2 K  .L
h dV x W
2 x 0
Putting the
t values of
o C in equ
uation (4) dx h
2P 2P dPP 2K
ln P  x  ln
l 2K  .L or   0
h h dxx h
§ P · 2P 2K
or ln ¨ ¸ L  x)
(L or ³ d P h ³ dxx
© 2K ¹ h
2P 2K
§ P · or P  x C .......(6)
or ln ¨ ¸ L  x)
(L h
© 2K ¹ h

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Boundary condition ns, at x = L, V x 0 (because

( no
o force is applied soo no stresss on that d P 2P P
or   0
surface) and Vx  P 2K gives P = 2 K dx h
2K L dP 2P
So, 2K  C or ³ P  h ³ dx
h
2K 2P
or C 2K  .L or ln P  x C ......(4)
h h
Putting in
i equation
n (6) Boundary conditions, at x = L, V x 0 (because no force is applied so no stress on that
2K 2K surface) and Vx  P 2 K gives P = 2 K
P  .x 2
2K  .L
h h 2P
or ln 2 K LC
2K
2 h
P 2K  (L  x ) …..... (7) {Presssure distriibution equ
uation} or C ln 2 K 
2P
.L
h h
2K Putting the values of C in equation (4)
At x = 0, Pmax K
2K .L
h 2P 2P
ln P  x  ln 2 K  .L
x = L, Pmin 2K h h
§ P · 2P
2k + 2k .L or ln ¨ ¸
© 2K ¹ h
(L  x )
h
§ P · 2P
or ln ¨ ¸ (L  x )
© 2K ¹ h
2P
(L  x )
h
or P 2K . e .... (5)
2h 2k dV x W
For Sticking Region: 2 x 0
dx h
dP 2K
or   0
dx h
x=0 x=L
Elementa
al force, dF = P . B . dx 2 K
or ³ d P h ³ dx
­ 2K ½
or dF = ®2K
K (L  x ) ¾ B . dx 2K
¯ h ¿ or P  x C ......(6)
L
h
­ 2K ½
F 2 u ³ ®2K  L  x ) ¾ B . dx
(L x At x xs ; P Ps
0¯ h ¿
2K
Ps  xs  C
or h
Condition-3: 2K
C Ps  . xs
Consid
dering sticking an
nd slidin
ng both model
m off friction or h
(' Temperatu
T re is same throughout body)
2K 2K
P  x  Ps  xs
h h
2K
P Ps  ( xs  x ) ...............(8)
h

dVx 2Wx
For Slidiing Region:  0
dx h

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Example 2: L = 50 mm, h = 10 mm & P 0.08

h § 1 · 10 § 1 ·
xs L ln ¨ ¸ 50  ln ¨ ¸  64.53 mm absurd value ¬
2P © 2P ¹ 2 u 0.08 © 2 u 0.08 ¹
(' x cannot be –ve) i.e only sliding no sticking occur.
Example 3: L = 50 mm, h = 10 mm & P 0.65
h § 1 · 10 § 1 ·
xs L ln ¨ ¸ 50  ln ¨ ¸ 52.01 mm ¬
2P © 2P ¹ 2 u 0.65 © 2 u 0.65 ¹
Only sticking no sliding
NOTE: If P ! 0.5 then only sticking, In hot forging ( P ) is larger if P ! 0.5 only sticking
condition will occur.

IES – 2005 Conventional

A strip of lead with initial dimensions 24 mm x 24 mm x 150 mm is forged between two flat
dies to a final size of 6 mm x 96 mm x 150 mm. If the coefficient of friction is 0.25,
FTotal FSticking  FSliding determine the maximum forging force. The average yield stress of lead in tension is 7
Xs L N/mm2
2 ³P 0
Sticking . B . dx  2 ³P
Xs
Sliding . B dx
d Solution: h = 6 mm, 2L = 96 mm, P 0.25
xs
h § 1 · 6 § 1 ·
2K
L
­ 2P
(L  x ) ½ xs L ln ¨ ¸ 48  ln 39.68 mm
­
2 ³ ®Ps 
½
( x s  x ) ¾ B . dx  2 ³ ®2K e h
°
¾ B . dx 2P © 2P ¹ 2 u 0.25 ¨© 2 u 0.25 ¸¹
0 ¯ h ¿ xs ¯ °¿ xS L 2P
2K
Ftotal = 2 u ³ ­®Ps  ½ (L  x )
( x s  x ) ¾ B. dx  2 u ³ 2 K e h
B . dx
0 ¯ h ¿ xS
To find Ps and x s
V0
At x x s , Shear strresses are same
s for booth sticking
g and slidin
ng Applying Von-Mises theory K 4.04 N / mm2
3
Wx K (if consid
dering stick
king)
K
Wx P Ps dering sliding)
(if consid Ps 16.16 N / mm2
or P
Wx K P Ps 39.68 48 2u0.25
­ 2 u 0.25 ½ (48  x )

Ps
K
....(9) or F 2u ³
0
®16.16 
¯ 6
39.68  x ¾ ˜ 150 . dx  2 u ³ (2 u 4.04) e
¿ 39.68
6
˜ 150 . dx
P
510 kN  29.10 kN 539 kN (Von  Mises)
At x xs ; P Ps
Vo K 3.5
2P
(L  x s ) Applying Tresca’s Theory, K 3.5 N / mm2 ; Ps 14 N / mm2
Ps 2K e h 2 P 0.25
2P 39.68 2u0.25 48
K h
(L  xs ) ­ 2 u 3.5 ½ (48  x )

P
2K e F 2u
®14 
¯
³ 6
(39.68  x ) ¾ ˜ 150 ˜ dx 2 ³ (2 u 3.5) e 6
¿
˜ 150 ˜ dx
or 0 39.68

1 2P
(L  xs ) 442 kN  25 kN 467kN (Tresca ' s)
eh
or 2P
§ 1 · 2P Practice Problem-1
ln ¨ ¸ (L  x s )
or © 2P ¹ h A strip of metal with initial dimensions 24 mm x 24 mm x 150 mm is forged between two
h § 1 · flat dies to a final size of 6 mm x 96 mm x 150 mm. If the coefficient of friction is 0.05,
. ln ¨ ¸ L  xs
2P © 2P ¹
determine the maximum forging force. Take the average yield strength in tension is 7
h § 1 ·
xs L ln ¨ ¸ ....(10) (in any ques
stion first w
we find thiss xs )
2P © 2P ¹ N/mm2
Using this equation
n we can deecide the coondition of friction.
f
Given: 2L = 96 mm; L = 48 mm; h = 6 mm; B = 150 mm; P 0.05
Example 1: L = 50 mm, h = 10 mm & P 0.25
h § 1 ·
h § 1 · 10 § 1 · xs L ln K = 4.04 N/mm2
xs L ln
n¨ ¸ 50  ln
n¨ ¸ 36.13mm 2P ¨© 2P ¸¹
2P © 2P ¹ 2 u 0.25 © 2 u 0.25 ¹
xs  90.155 mm
0 to 36.13 mm stick
king and 36
6.13 mm to 50 mm slid
ding will ta
ake place.
Since xs came negative so there will be no sticking only sliding will take place.

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L 2P
(L  x )
F 4 KB ³ e h dx
0

48 °­§ 2u0.05 · °½
®¨ ¸(48  x ) ¾
¯°© 6 ¹ ¿°
4 u 4.04 u 150 ³e
0
dx 177.98 kN

Axi – Symmetrical Forging (Open Die):

Using cylindrical co-ordinate system (r, T, z )
and Using Slab Method of analysis
d1

R
h1

At the start At end of forging

Net resultant force in radially
y outward direction
d is 0.
of forging
dT
( Vr  d Vr ) (r  dr ) dT . h  ( Vr . r dT . h )  2 Wr . r dT . dr  2 V T dr h . ssin 0
2
Volume before forging = Volume after forging
S 2
d1 u h1 S R 2 h VTdr.h cos dT
4 2
At an angle T, we take an dT element at a radius r we take dr element.
VV dVr
VTdr.h cos dT
2
dT
dr VT dr 2
dT

VT dVT
VT
r VT drh
Vr 
T
dT
VTdr.h sin dT 2 VTdr.h sin dT
2 2

For axi-symmetrical forging dV T will be zero. § dT

ncelled ? the
·
¨ coss gets can ey are oppossite ¸
© 2 ¹

For Axi--Symmetr
ry forging
r T
i.e. Vr V T
From aboove equatioon,
dT
( Vr  d Vr ) ( r  dr ) dT . h  ( Vr . r dT . h )  2 Wr . r dT . dr  2 Vr dr h . 0
2
§ d T dT ·
¨ U sin g : V T Vr ; sin | ¸
© 2 2 ¹
Vr  d Vr ) (r  dr ) . h  ( Vr . rh)  2Wr . r dr  Vr . dr
(V d .h 0
or

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( Vr . r . h  dVr . rh  dVr . drh  Vr drr . h)  Vr . rh

h  2Wr . r drr  Vr dr. h 0 2 PR
or C ln V0 
d Vr . r h 2Wr . r dr or h
or
d V r 2 Wr 2Pr 2 PR
 0 ...(1) uation (4)
From equ ln P   ln V0 
or d
dr h h h
For ductiile materia
al there are two theoriies of plastiicity P 2P
ln (R  r )
1. Tresca’s Theory y: V0 h
or
2P
(R  r )
P V0 . e h ………
……….. (5) Pressure distribution
n
or
2P
.R
At r = 0; Pmax V0 e h

At r = R; Pmin V0
Here r = 0 means a point

V1  V3 V0
Vr  P V0 ...(2)
or
2. Von Miscs
M Theo
ory:
V1  V2 )2  ( V2  V3 )2  ( V3  V1 )2
(V 2 V20
2 2 2
( Vr  Vr )  ( Vr  P)  (  P  Vr ) 2 V20 ding force
For find
or
2 ( Vr  P)2 2 V20 Elementaal force (dF
F)
or
V P
r 0V ...(2)
or dr
On differrentiating; r R
d Vr d P
 0
dr dr
d Vr dP
 ...(3)
dr dr Sr dr
dA = 2S

dF = d F P . 2Sr . drr
Condittion 1: 2P
(R  r )

Consid
dering sliding
s f
friction all over
r the sur
rface ³dF ³V 0 .eh . 2Sr . dr
R 2P
Wr PP . (R  r )
orr F 2SV0 ³ r.e h
dr
d P 2Wr
From (1) and (3);   0 0
dr h ª
R
2P
(R  r ) § 2P
(R  r ) ·º
dP PP «r . e h eh »
 2. 0 orr F 2SV0 «  ³ ¨¨1 . d ¸¸ »
dr
or dr h § 2P · § 2P ·
« ¨ ¸ ¨ ¨  ¸ ¸»
dP 2 P P ¬ © h ¹ © © h ¹ ¹¼ 0
R
or dr h ª 2P
(R  r )
2P
(R  r ) º
r.eh eh
dP 2P orr F 2SV0 «  »
or « § 2P · P· »
2
³P ³
h
. dr
« ¨ ¸ §
¨
2
 ¸ »
«¬ © h ¹ © h ¹ ¼» 0
2P
ln P  .r C ...(4) ª 2P
R º
h R 1 eh
At r = R; Vr 0 (becausse on this su
urface therre will be noo force) and
d Vr  P V 0 ; P V0 orr F 2S V 0 «  0 »
« § 2P · 2 P
2
2 P
2 »
«¨ § · § · »
¸ ¨ ¸ ¨ ¸
2P . R «¬ © h ¹ © h ¹ © h ¹ ¼»
ln V0  C
or h

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2K
C V0  R
h
IES–2007Conventional or
2K 2K
From (6) P  . r  V0  R
A cylinder of height 60 mm and diameter 100 mm is forged at room temperature between h h
two flat dies. Find the die load at the end of compression to a height 30 mm, using slab 2
2K
P V0  . (R  r ) ...(7) Pressure Distribution
n linear
method of analysis. The yield strength of the work material is given as 120 N/mm2 and the h
or
coefficient of friction is 0.05. Assume that volume is constant after deformation. There is no
2K
sticking. Also find mean die pressure. [20-Marks] At r = 0; Pmax V0  .R
h
Solution: Given, h1 = 60 mm, d1 = 100 mm, h = 30 mm r = R; Pmin V0
V0 120 N/ mm 2 and P 0.05
S d12
h1 S R2 h
or 4
2
100
u 60 R2 u 30
or 4
or R = 70.7 mm
2P
ª .Rº
R 1 eh
F 2S V 0 «  0 » 2.04 MN
« § 2P · 2 2 »
«¨ § 2P · § 2P · »
¸ ¨ ¸ ¨ ¸
¬« © h ¹ © h ¹ © h ¹ »¼
Total force 2.04 u 106
Mean Die pressure = | 130 MPa
Total Area S u 70.72
For find
ding force:
GATE–2014(PI)
In an open die forging, a circular disc is gradually compressed between two r
flat platens. The exponential decay of normal stress on the flat face of the
disc, from the center of the disc towards its periphery, indicates that R
(a) there is no sticking friction anywhere on the flat face of the disc
(b) sticking friction and sliding friction co-exist on the flat face of the disc 2Srdr

(c) the flat face of the disc is frictionless

dF P . 2 Sr dr
d
(d) there is only sticking friction on the flat face of the disc
Answer: (a) or F ³ P . 2 Sr dr
d
R
ª 2K
K º
F ³ «¬V 0  . (R  r ) » 2S r dr
Condition -2: Considering sticking friction all over the or 0 h ¼

surface
Wr K
From (1) equation (3)
d V r 2 Wr
 0
dr h
d P 2K
  0
or dr h
2K
or ³dP ³
h
. dr

2K
or P  .r C ...(6)
h
At r = R; Vr 0 (because on this surface there will be no force) and Vr  P V0 ; P V0
2K
V0  .RC
h

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Condition 3: Rs R
h § K ·
ln ¨
When there is sticking and sliding both frictions occur © 2P P V0 ¸¹
or
According to Tresca’s theory
V0 K 1
K or
2 V0 2
g
di n
Sl i Sliding Rs R
h § 1 ·
ln ¨ ¸ ...(10)
2P © 2P ¹

ng
ki
ic Ps According to Von-Miscs Theory
St
Sticking V0 K 1
r = Rs K or
3 V0 3
h § 1 ·
Rs R ln ¨ ¸ ...(11)
2P © 3 P¹

IES–2006–Conventional
A certain disc of lead of radius 150 mm and thickness 50 mm is reduced to a thickness of 25
mm by open die forging. If the co-efficient of friction between the job and die is 0.25,
For sliding region pressure distribution is same as we derived in previous condition same
determine the maximum forging force. The average shear yield stress of lead can be taken
boundary condition same differential equation.
2P
(R  r )
as 4 N/mm2 [10 – Marks]
P V0 . e h
Solution: R1 = 150 mm, h1 50 mm, R = ?, h = 25 mm, Ǎ= 0.25

For sticking region: Using equation (6). SR12h1 S R2 h

2K R = 212.1 mm
P  .r C
h W y 4 N/ mm2 (Shear yield stress) = K
Boundary condition at r = R; P Ps By Tresca Theory;
2K 25 § 1 ·
or Ps  . Rs  C Rs 212.1  ln ¨ ¸ = 177.4 mm
h 2 u 0.25 © 2 u 0.25 ¹
2K ª0 mm to 177.4 mm o sticking º
C Ps  . Rs
or h «177.4 mm to 212.1mm o sliding »
Putting in equation (6)
¬ ¼
K 4
2K 2K Ps 16 N / mm2
P  (r )  Ps  Rs P 0.25
h h
2K V0 2K 2u4 8 N / mm2
P Ps  . (R s  r ) ...(8) °­§ 2u0.25 · ½°
h ­177.4
§2u4· ½ 212.1
®¨ ¸(212.1  r ) ¾
or °© 25 ¹ ¿°

FTotal Fsticking  Fsliding

Ftotal ³ (8) u e ¯
³0 ®¯16  ¨© 25 ¸¹ (177.4  r )¾¿ . 2 Sr dr  177.4 . 2 Sr dr

Rs R 3.93 MN (Tresca’s Theory)

Ftotal ³P
0
sticking ˜ 2 Sr dr  ³P
Rs
sliding ˜ 2 Sr dr Von Miscs Theory;
25 § 1 ·
Rs 212.1  ln ¨ ¸ = 170.25 mm
Rs R 2P
ª 2K º (R  r )
2 u 0.25
Ftotal ³ «¬P s  (R s  r )» ˜ 2 Sr dr  ³V 0 .e h
. 2 Sr dr © 3 u 0.25 ¹
0
h ¼ Rs
ª0 mm to 170.25 mm o sticking º
To find Ps and Rs «170.25 mm to 212.1mm o sliding »
Wr P Ps K ¬ ¼
K 4
K Ps 16 N / mm2
Ps ......(9) P 0.25
or P
V0 K 3 4 3 N / mm2 
At r Rs ; P Ps
2P
(R  Rs )
RS
Ps V0 e h
­ 2K ½
R 2P
(R  r )

K 2P
(R  R s )
Ftotal ³ ®¯P
0
s 
h
(R s  r ) ¾ ˜ 2 Sr dr 
¿ RS
³V 0 eh ˜ 2 Sr dr
V0 e h

or P 170.25 2u0.25 212.1

­ 2u4 ½ (212.1  r )

§ K · 2P
Ftotal
¯
³
®16 
25
(170.25  r ) ¾ ˜ 2 Sr dr  ³ 4 3. e 25
¿
˜ 2 Sr dr
ln ¨ ¸ (R  R s ) 0 170.25

© P V0 ¹ h = 3.6 MN (Von Misces)

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Practice Problem -1 d1 150 mm; h1 100 mm; h 50 mm; P 0.2;

A strip of metal with initial dimensions 24 mm x 24 mm x 150 mm is forged between two flat dies to a ' Volume before forging = Volume after forging
final size of 6 mm x 96 mm x 150 mm. If the coefficient of friction is 0.05, determine the maximum
forging force. Take the average yield strength in tension is 7 N/mm2 S S
d12 h1 S R 2 h or u 1502 u100 S R 2 u 50 Ÿ R 106.66 mm
4 4
Answer:
h 50
True strain H ln ln 0.693
Given: 2L = 96 mm; L = 48 mm; h = 6 mm; B = 150 mm; P 0.05
h1 100
Flow stress V o Vf 1030H 0.17
1030 u 0.6930.17 967.74 MPa
h § 1 ·
xs L ln K = 4.04 N/mm2 By Tresca Theory;
2P ¨© 2P ¸¹
50 § 1 ·
xs  90.155 mm Rs 106.66  ln ¨ ¸ =-7.87mm
2 u 0.2 © 2 u 0.2 ¹
Since xs came negative so there will be no sticking only sliding will take place. VonMiscsTheory;
L 2P
(L  x )
F 4 KB ³ e h dx
0 Practice Problem -4
48 °­§ 2u0.05 ·
®¨
°½
¸ (48  x ) ¾
A circular disc of 200 mm in diameter and 70 mm in height is forged to 40 mm in height.
¯°© 6 ¹ ¿°
4 u 4.04 u 150 ³e dx 177.98 kN Coefficient of friction is 0.05. The flow curve equation of the material is given by
0
Vf 200(0.01  H )0.41 MPa . Determine maximum forging load, mean die pressure and maximum
Practice Problem -2 pressure.
A circular disc of 200 mm in diameter and 100 mm in height is compressed between two flat dies to a
height of 50 mm. Coefficient of friction is 0.1 and average yield strength in compression is 230 MPa. Answer:
Determine the maximum die pressure.
d1 200 mm; h1 70 mm; h 40 mm; P 0.05; V f 200(0.01  H )0.41
Answer: ' Volume before forging = Volume after forging
d1 200 mm; h1 100 mm; h 50 mm; P 0.1; V Y 230 MPa V O S S
' Volume before forging = Volume after forging d12 h1 S R 2 h or u 2002 u 70 S R 2 u 40 Ÿ R 132.28 mm
4 4
S S h 40
d 2 h S R 2 h or u 2002 u100 S R 2 u 50 Ÿ R 141.421 mm True strain H ln ln 0.5596
4 1 1 4 h1 70
According to Von-Mises Vf 200(0.01  H )0.41
h § 1 · 50 § 1 · Vf 200(0.01  0.5596)0.41 158.78 V o
Rs R  ln 141.21  ln 297.1 mm
2 P ¨© 3P ¸¹ 2 u 0.1 ¨© 3 u 0.1 ¸¹ NowuseTresca’stheory
According to Tresca
VonͲMisesTheory
h § 1 · 50 § 1 ·
Rs R
ln 141.21  ln 261.1 mm
2P ¨© 2P ¸¹ 2 u 0.1 ¨© 3 u 0.1 ¸¹ Practice Problem -5 {GATE-2010 (PI)}
During open die forging process using two flat and parallel dies,
' Rs came out to be negative so only sliding friction takes place.
a solid circular steel disc of initial radius (R IN ) 200 mm and initial
The formula for pressure we get after the slab method of analysis of forging;
2P height (H IN ) 50 mm attains a height (H FN ) of 30 mm and radius of R FN .
Rr
P V oe h Along the die-disc interfaces.
at r 0; P Pmax R
§  IN ·
2u0.1
(141.21) i. the coefficient of friction (P ) is: P = 0.35 ¨ 1  e RFN ¸
Pmax 230 u e 50 404.94 MPa ¨ ¸
© ¹
ii. in the region R ss d r d RFN ,sliding friction prevails, and
Practice Problem -3 2P
A cylindrical specimen 150 mm in diameter and 100 mm in height is upsetted by open RFN  r

die forging to a height of 50 mm. Coefficient of friction is 0.2 and flow curve equation is p 3Ke H FN and W P p,
V f 1030H 0.17 MPa . Calculate the maximum forging force. where p and W are the normal and shear stresses, respectively;
K is the shear yield strength of steel and r is the radial distance
Answer: of any point

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iii.In the region 0 d r d R SS ,sticking condition prevails

The value of R SS (in mm), where sticking condition changes to sliding
friction, is
(a) 241.76 (b) 254.55 (c) 265.45 (d) 278.20

Answer:
S RIN2 H IN 2
S RFN H FN
2 2
or 200 u 50 RFN u 30 Ÿ RFN 258.2 mm
200
§  ·
and P 0.35 ¨1  e 258.2 ¸ 0.51
© ¹
Now at Rss
Shear stress in sticking K = shear stress in sliding P Pss
2P
RFN  Rss
or K = P 3Ke H FN
§ 1 · 2P
or ln ¨ ¸ RFN  Rss
© 3P ¹ H FN
H § 1 ·
or FN ln ¨ ¸ RFN  Rss
2 P © 3P ¹
H § 1 · 30 § 1 ·
or Rss RFN  FN ln ¨ ¸ 258.2  ln 254.55 mm
2P © 3P ¹ 2 u 0.51 ¨© 3 u 0.51 ¸¹
IFS-2012
Discuss Tresca and Von Mises yield criterion for metal forming operations. Also derive tensile and
shear yield stress relationships for their approaches. Which of this criterion is more realistic? Why?
[10 Marks]
Answer: Refer forging analysis

For-2019(IES, GATE & PSUs) Page 198 of 203 Rev.0