Handbook of Workability and Process Design

Transcription

1 Handbook of Workability and Process Design Edited by Howard A. Kuhn S. Lee Semiatin INTERNATIONAL The Materials Information Society R

2 Copyright 2003 by ASM International All rights reserved No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the written permission of the copyright owner. First printing, September 2003 Great care is taken in the compilation and production of this book, but it should be made clear that NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE GIVEN IN CONNECTION WITH THIS PUBLICATION. Although this information is believed to be accurate by ASM, ASM cannot guarantee that favorable results will be obtained from the use of this publication alone. This publication is intended for use by persons having technical skill, at their sole discretion and risk. Since the conditions of product or material use are outside of ASM s control, ASM assumes no liability or obligation in connection with any use of this information. No claim of any kind, whether as to products or information in this publication, and whether or not based on negligence, shall be greater in amount than the purchase price of this product or publication in respect of which damages are claimed. THE REMEDY HEREBY PROVIDED SHALL BE THE EXCLUSIVE AND SOLE REMEDY OF BUYER, AND IN NO EVENT SHALL EITHER PARTY BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHETHER OR NOT CAUSED BY OR RESULTING FROM THE NEGLIGENCE OF SUCH PARTY. As with any material, evaluation of the material under end-use conditions prior to specification is essential. Therefore, specific testing under actual conditions is recommended. Nothing contained in this book shall be construed as a grant of any right of manufacture, sale, use, or reproduction, in connection with any method, process, apparatus, product, composition, or system, whether or not covered by letters patent, copyright, or trademark, and nothing contained in this book shall be construed as a defense against any alleged infringement of letters patent, copyright, or trademark, or as a defense against liability for such infringement. Comments, criticisms, and suggestions are invited, and should be forwarded to ASM International. ASM International staff who worked on this project include Steve Lampman, Acquisitions Editor; Bonnie Sanders, Manager of Production; Carol Terman, Jill Kinson, and Nancy Hrivnak, Production Editors; and Scott Henry, Assistant Director of Reference Publications. Library of Congress Cataloging-in-Publication Data Handbook of workability and process design / edited by, Howard A. Kuhn, Lee Semiatin. p. cm. Updated and expanded ed. of: Workability testing techniques ISBN Metals Formability Testing. I. Dieter, George Ellwood. II. Kuhn, Howard A. III. Semiatin, S. L. IV. Workability testing techniques. TA460.H dc ISBN: SAN: ASM International Materials Park, OH Printed in the United States of America Multiple copy reprints of individual articles are available from ASM International, Technical Department.

3 Contents Preface vi Introduction Chapter 1 Workability and Process Design An Introduction Howard A. Kuhn,, and S.L. Semiatin Workability Problems Process Design and Modeling Approximate and Closed Form Solutions Numerical Techniques in Process Modeling Microstructural Modeling Processing Maps Summary Chapter 2 Bulk Workability of Metals Stress, Strain, and Stress-Strain Curves Multiaxial Stress States Material Factors Affecting Workability Process Variables Determining Workability Workability Fracture Criteria Process Maps Summary Chapter 3 Evolution of Microstructure during Hot Working S.L. Semiatin Mechanisms of Microstructure Evolution Phenomenology of Plastic Flow and Microstructure Evolution Mechanistic Models for Microstructure Evolution Workability Testing Techniques Chapter 4 Bulk Workability Testing Primary Tests Specialized Tests Workability Analysis Using the Fracture Limit Line Chapter 5 Cold Upset Testing Howard A. Kuhn Upset Test Technique Test Characteristics Fracture Limits Workability Diagram Conclusions Chapter 6 Hot Compression Testing Cylindrical Compression Test Ring Compression Test Plane-Strain Compression Test Conclusions Chapter 7 Hot-Tension Testing P.D. Nicolaou, R.E. Bailey, and S.L. Semiatin Equipment and Testing Procedures Hot Ductility and Strength Data from the Gleeble Test Isothermal Hot-Tension Test Data Modeling of the Isothermal Hot-Tension Test Cavitation During Hot-Tension Testing Chapter 8 Torsion Testing to Assess Bulk Workability S.L. Semiatin and J.J. Jonas Material Considerations Specimen Design Torsion Equipment Flow-Stress Data Interpretation of Torsion Fracture Data Measuring Flow-Localization-Controlled Workability Microstructure Development During Deformation Processing Processing History Effects Chapter 9 Hot Working Simulation by Hot Torsion Testing Joseph R. Pickens Types of Hot Working Simulation Tests Hot Torsion Testing Practice Hot Torsion Application Examples Chapter 10 Thermomechanical Testing Stéphane Guillard and Koushik Ray Typical Types of Problems Thermophysical Properties Tests Designing Thermomechanical Tests Obtaining, Analyzing, and Using Thermomechanical Testing Results Examples of Thermomechanical Testing: Design, Experiment, and Analysis Process Design and Workability Chapter 11 Design for Deformation Processes Why Use Deformation Processes? Characteristics of Manufacturing Processes Categories of Deformation Processes Cold Working Hot Working Forgeability of Alloys Summary Chapter 12 Workability Theory and Application in Bulk Forming Processes Howard A. Kuhn Stress and Strain States Empirical Criterion of Fracture Theoretical Fracture Models and Criteria Applications iii

4 Chapter 13 Workability in Forging S.L. Semiatin Workability Tests for Open-Die Forging of Cast Structures Workability Tests for Hot/Warm Open-Die Forging of Recrystallized Structures Workability Tests for Cold Open-Die Forging of Recrystallized Structures Workability in Closed-Die Forging Summary Chapter 14 Process Design in Impression Die Forging T. Altan and M. Shirgaokar Forging Process Variables Design of Finisher Dies Preform (Blocker) Design in Impression-Die Forging Prediction of Forging Stresses and Loads Process Simulation to Predict Metal Flow and Forging Stresses Cold and Warm Forging Chapter 15 Modeling Techniques in Forming Processes W.T. Wu, J.T. Jinn, and C.E. Fischer Modeling Techniques Finite Element Method Heat Transfer Example Simulations Current and Future Works Chapter 16 Rolling Flat Rolling Modeling of Strip Rolling Mechanics of Plate Rolling Shape Rolling Summary Chapter 17 Thermomechanical Processing by Controlled Rolling Fundamentals of Controlled Rolling Restoration Processes Conventional Controlled Rolling Recrystallization Controlled Rolling Thermomechanical Processing of Microalloyed Bar Summary and Acknowledgment Chapter 18 Workability and Process Design in Rolling John G. Lenard The Rolling Process Workability in Rolling Mathematical Models for Workability Prediction Process Design Conclusions Chapter 19 Drawing of Wire, Rod, and Tube Drawing of Bar and Wire Tube Drawing Lubrication Wear Conclusions Chapter 20 Extrusion Extrusion Methods The Extrusion Process Friction and Lubrication iv Forward (Direct) Extrusion Backward (Indirect) Extrusion Cold Extrusion Hot Extrusion Hydrostatic Extrusion Summary Chapter 21 Workability and Process Design in Extrusion and Drawing Roger N. Wright Multipass Workability versus Single-Pass Workability General Observations on Fracture and Flaw Development Shapes and Tubes Some Comments on Fracture Mechanisms Projecting Workability from Mechanical Tests Process Design Multidisciplinary Process Design and Optimization Chapter 22 Multidisciplinary Process Design and Optimization: An Overview H.L. Gegel, R. Grandhi, J.S. Gunasekera, and Charles Gure Why Use MPDO? Process Design Methods Computer Aided Optimization Manual Design Process Chapter 23 Optimal Design of Thermomechanical Processes J.C. Malas, W.G. Frazier, H.L. Gegel, and V. Srinivasan Concepts of Dynamic Modeling in Optimal Design Material Trajectory Optimization Chapter 24 Application of Multidisciplinary Optimization (MDO) Techniques to the Manufacturing of Aircraft Engine Components Shesh K. Srivatsa Turbine Disk Design and Manufacturing Optimization Techniques Collaborative Optimization Environment Formulation of Forging Shape Optimization Alternative Forging Optimization Formulations Heat Treatment Optimization Summary of Optimization Techniques Conclusions Future Work Chapter 25 Computer-Aided Optimization for Improved Process Engineering Productivity of Complex Forgings Ramana V. Grandhi Computer-Aided Optimization (CAO) Discussion Reference Information Tabular Summaries of Typical Flow Stress Data Table 1 K and n values for flow stress-strain relation, s K( e ) n, of various steels Table 2 C and m values for the flow stress-strain rate relation, s C( e ) m, of steels at various temperatures Table 3 K and n values for the flow stress-strain relation, s K( e ) n, of various aluminum alloys Table 4 C and m values for the flow stress-strain rate relation, s C( e ) m, of aluminum alloys at various temperatures Table 5 K and n values for the flow stress-strain relation, s K( e ) n, of various copper alloys

5 Table 6 C and m values for the flow stress-strain rate relation, s C( e ) m, of various nonferrous alloys Table 7 Average flow stress values determined in the uniform compression test that might be used in practical load-predicting applications Table 8 Average flow stress values obtained from ring compression tests suggested for use in practical applications. 385 Abbreviations and Symbols Index v

6 Preface Workability is a vital aspect of the processing of materials, having roots in both material behavior and process design. Whether a part can be produced by plastic deformation without cracking or the generation of other defects is of important economic consequence. Because of the complex nature of the workability of metals, there is no single test that can be used to evaluate it. Several laboratory tests have been developed that are useful in screening materials for workability, but in other instances, very specialized tests that are specific to the process are commonly used. The Handbook of Workability and Process Design is an update and expansion in scope of Workability Testing Techniques that was published by the American Society for Metals in This original work was developed by the Metal Working Group of ASM to provide a readily available description and interpretation of the most common workability tests in the deformation processing of metals. Prior to its introduction, this information was widely scattered in the literature. The nearly 20 year life of this book bears witness to the value and acceptance of the concept behind this project. At the time of the formulation of Workability Testing Techniques, the use of finite element methods (FEMs) for the modeling and simulation of metal deformation processes was in its infancy. In the ensuing 20 years, the use of FEM analysis for process design has become rather commonplace. Therefore, in contemplating this revision and update, the editors decided to expand the scope to incorporate process design, especially as influenced by FEM analysis. By doing this, the Handbook of Workability and Process Design takes on a more mathematical flavor than its predecessor while still retaining a balance with its original intent. Thus, the chapters that describe the various workability tests continue true to the original intent of providing practical workability testing techniques that can be used by the inexperienced practitioner. We appreciate the contributions from the many experts who have contributed to this Handbook. Also, special thanks go to Steve Lampman, of the ASM staff, who not only provided editorial guidance throughout this project but also expertly provided the chapters that describe the basics of forging, rolling, extrusion, and wiredrawing. Howard A. Kuhn S. Lee Semiatin College Park, MD Johnstown, PA Dayton, OH May 1, 2003 May 1, 2003 May 1, 2003 vi

7 ASM International is the society for materials engineers and scientists, a worldwide network dedicated to advancing industry, technology, and applications of metals and materials. ASM International, Materials Park, Ohio, USA This publication is copyright ASM International. All rights reserved. Publication title Product code Handbook of Workability and Process Design #06701G To order products from ASM International: Online Visit /bookstore Telephone (US) or (Outside US) Fax Mail Customer Service, ASM International 9639 Kinsman Rd, Materials Park, Ohio , USA CustomerService@asminternational.org In Europe In Japan American Technical Publishers Ltd Knowl Piece, Wilbury Way, Hitchin Hertfordshire SG4 0SX, United Kingdom Telephone: (account holders), (credit card) Neutrino Inc. Takahashi Bldg., 44-3 Fuda 1-chome, Chofu-Shi, Tokyo 182 Japan Telephone: 81 (0) Terms of Use. This publication is being made available in PDF format as a benefit to members and customers of ASM International. You may download and print a copy of this publication for your personal use only. Other use and distribution is prohibited without the express written permission of ASM International. No warranties, express or implied, including, without limitation, warranties of merchantability or fitness for a particular purpose, are given in connection with this publication. Although this information is believed to be accurate by ASM, ASM cannot guarantee that favorable results will be obtained from the use of this publication alone. This publication is intended for use by persons having technical skill, at their sole discretion and risk. Since the conditions of product or material use are outside of ASM's control, ASM assumes no liability or obligation in connection with any use of this information. As with any material, evaluation of the material under end-use conditions prior to specification is essential. Therefore, specific testing under actual conditions is recommended. Nothing contained in this publication shall be construed as a grant of any right of manufacture, sale, use, or reproduction, in connection with any method, process, apparatus, product, composition, or system, whether or not covered by letters patent, copyright, or trademark, and nothing contained in this publication shall be construed as a defense against any alleged infringement of letters patent, copyright, or trademark, or as a defense against liability for such infringement.