Hosford W.F. Metal forming: mechanics and metallurgy / W.F.Hosford, R.M.Caddell (Cambridge; New York, 2011). - ОГЛАВЛЕНИЕ / CONTENTS
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ОбложкаHosford W.F. Metal forming: mechanics and metallurgy / W.F.Hosford, R.M.Caddell. - 4th ed. - Cambridge; New York: Cambridge University Press, 2011. - xii, 331 p.: ill. - Ind.: p.327-331. - ISBN 978-1-107-00452-8
 

Оглавление / Contents
 
Preface to the Fourth Edition ................................. xii
1  Stress and Strain ............................................ 1
   1.1  Stress .................................................. 1
   1.2  Stress transformation ................................... 2
   1.3  Principal stresses ...................................... 4
   1.4  Mohr's circle equations ................................. 5
   1.5  Strain .................................................. 7
   1.6  Small strains ........................................... 9
   1.7  The strain tensor ...................................... 10
   1.8  Isotropic elasticity ................................... 10
   1.9  Strain energy .......................................... 11
   1.10 Force and moment balances .............................. 12
   1.11 Boundary conditions .................................... 13
   NOTES OF INTEREST ........................................... 14
   REFERENCES .................................................. 15
   APPENDIX - EQUILIBRIUM EQUATIONS ............................ 15
   PROBLEMS .................................................... 15
2  Plasticity .................................................. 17
   2.1  Yield criteria ......................................... 17
   2.2  Tresca criterion ....................................... 18
   2.3  Von Mises criterion .................................... 20
   2.4  Effective stress ....................................... 21
   2.5  Effective strain ....................................... 22
   2.6  Flow rules ............................................. 23
   2.7  Normality principle .................................... 24
   2.8  Derivation of the von Mises effective strain ........... 26
   NOTES OF INTEREST ........................................... 27
   REFERENCES .................................................. 28
   PROBLEMS .................................................... 28
3  Strain Hardening ............................................ 30
   3.1  The tension test ....................................... 30
   3.2  Elastic-plastic transition ............................. 32
   3.3  Engineering vs. true stress and strain ................. 32
   3.4  Power-law expression ................................... 34
   3.5  Other strain-hardening approximations .................. 36
   3.6  Behavior during necking ................................ 36
   3.7  Compression testing .................................... 38
   3.8  Bulge testing .......................................... 38
   3.9  Plane-strain compression ............................... 39
   3.10 Torsion testing ........................................ 40
   NOTE OF INTEREST ............................................ 40
   REFERENCES .................................................. 41
   PROBLEMS .................................................... 41
4  Plastic Instability ......................................... 43
   4.1  Uniaxial tension ....................................... 43
   4.2  Effect of inhomogeneities .............................. 44
   4.3  Balanced biaxial tension ............................... 45
   4.4  Pressurized thin-wall sphere ........................... 47
   4.5  Significance of instability ............................ 48
   NOTE OF INTEREST ............................................ 49
   REFERENCES .................................................. 49
   PROBLEMS .................................................... 49
5  Temperature and Strain-Rate Dependence ...................... 52
   5.1  Strain rate ............................................ 52
   5.2  Superplasticity ........................................ 55
   5.3  Effect of inhomogeneities .............................. 58
   5.4  Combined strain and strain-rate effects ................ 62
   5.5  Alternative description of strain-rate dependence ...... 63
   5.6  ti, Temperature dependence of flow stress .............. 65
   5.7  Deformation mechanism maps ............................. 69
   5.8  Hot working ............................................ 69
   5.9  Temperature rise during deformation .................... 71
   NOTES OF INTEREST ........................................... 72
   REFERENCES .................................................. 73
   PROBLEMS .................................................... 73
6  Work Balance ................................................ 76
   6.1  Ideal work ............................................. 76
   6.2  Extrusion and drawing .................................. 77
   6.3  Deformation efficiency ................................. 78
   6.4  Maximum drawing reduction .............................. 79
   6.5  Effects of die angle and reduction ..................... 80
   6.6  Swaging ................................................ 81
   REFERENCES .................................................. 82
   PROBLEMS .................................................... 82
7  Slab Analysis ............................................... 85
   7.1  Sheet drawing .......................................... 85
   7.2  Wire and rod drawing ................................... 87
   7.3  Friction in plane-strain compression ................... 88
   7.4  Sticking friction ...................................... 90
   7.5  Mixed sticking-sliding conditions ...................... 90
   7.6  Constant shear stress interface ........................ 91
   7.7  Axially symmetric compression .......................... 92
   7.8  Sand-pile analogy ...................................... 93
   7.9  Flat rolling ........................................... 93
   7.10 Roll flattening ........................................ 95
   7.11 Roll bending ........................................... 99
   7.12 Coming ................................................ 101
   7.13 Reducing the area of contact .......................... 101
   NOTES OF INTEREST .......................................... 102
   REFERENCES ................................................. 102
   PROBLEMS ................................................... 102
8  Friction and Lubrication ................................... 106
   8.1  General ............................................... 106
   8.2  Experimental findings ................................. 109
   8.3  Ring friction test .................................... 110
   8.4  Galling ............................................... 111
   8.5  Ultrasonics ........................................... 111
   NOTE OF INTEREST ........................................... 111
   REFERENCES ................................................. 112
   PROBLEMS ................................................... 112
9  Upper-Bound Analysis ....................................... 113
   9.1  Upper bounds .......................................... 113
   9.2  Energy dissipation on plane of shear .................. 114
   9.3  Plane-strain frictionless extrusion ................... 115
   9.4  Plane-strain frictionless indentation ................. 119
   9.5  Plane-strain compression .............................. 119
   9.6  Another approach to upper bounds ...................... 122
   9.7  A combined upper-bound analysis ....................... 123
   9.8  Plane-strain drawing .................................. 124
   9.9  Axisymmetric drawing .................................. 124
   REFERENCES ................................................. 126
   PROBLEMS ................................................... 126
10 Slip-Line Field Analysis ................................... 132
   10.1 Introduction .......................................... 132
   10.2 Governing stress equations ............................ 132
   10.3 Boundary conditions ................................... 136
   10.4 Plane-strain indentation .............................. 137
   10.5 Hodographs for slip-line fields ....................... 138
   10.6 Plane-strain extrusion ................................ 139
   10.7 Energy dissipation in a slip-line field ............... 141
   10.8 Metal distortion ...................................... 141
   10.9 Indentation of thick slabs ............................ 142
   10.10 Plane-strain drawing ................................. 146
   10.11 Constant shear stress interfaces ..................... 150
   10.12 Pipe formation ....................................... 151
   NOTES OF INTEREST .......................................... 152
   REFERENCES ................................................. 154
   APPENDIX ................................................... 154
   PROBLEMS ................................................... 157
11 Deformation-Zone Geometry .................................. 167
   11.1 The Д parameter ....................................... 167
   11.2 Friction .............................................. 168
   11.3 Redundant deformation ................................. 168
   11.4 Inhomogeneity ......................................... 170
   11.5 Internal damage ....................................... 175
   11.6 Residualstresses ...................................... 179
   11.7 Comparison of plane-strain and axisymmetric
        deformation ........................................... 182
   NOTE OF INTEREST ........................................... 184
   REFERENCES ................................................. 184
   PROBLEMS ................................................... 184
12 Formability ................................................ 186
   12.1 Ductility ............................................. 186
   12.2 Metallurgy ............................................ 186
   12.3 Ductile fracture ...................................... 190
   12.4 Hydrostatic stress .................................... 191
   12.5 Bulk formability tests ................................ 195
   12.6 Formability in hot working ............................ 196
   NOTE OF INTEREST ........................................... 197
   REFERENCES ................................................. 197
   PROBLEMS ................................................... 197
13 Bending .................................................... 199
   13.1 Sheet bending ......................................... 199
   13.2 Bending with super-imposed tension .................... 202
   13.3 Young's modulus on unloading .......................... 204
   13.4 Reducing springback ................................... 204
   13.5 Neutral axis shift .................................... 204
   13.6 Bendability ........................................... 206
   13.7 Shape bending ......................................... 207
   13.8 Forming limits in bending ............................. 208
   NOTE OF INTEREST ........................................... 209
   REFERENCES ................................................. 209
   PROBLEMS ................................................... 209
14 Plastic Anisotropy ......................................... 212
   14.1 Crystallographic basis ................................ 212
   14.2 Measurement of R ...................................... 214
   14.3 Hill's anisotropic plasticity theory .................. 214
   14.4 Special cases of Hill's yield criterion ............... 216
   14.5 Nonquadratic yield criteria ........................... 217
   14.6 Calculation of anisotropy from crystallographic
        considerations ........................................ 220
   NOTE OF INTEREST ........................................... 221
   REFERENCES ................................................. 221
   PROBLEMS ................................................... 221
15 Cupping, Redrawing, and Ironing ............................ 225
   15.1 Cup drawing ........................................... 225
   15.2 Anisotropy effects in drawing ......................... 228
   15.3 Effects of strain hardening in drawing ................ 229
   15.4 Analysis of assumptions ............................... 230
   15.5 Effects of tooling on cup drawing ..................... 232
   15.6 Earing ................................................ 233
   15.7 Redrawing ............................................. 235
   15.8 Ironing ............................................... 236
   15.9 Progressive forming ................................... 238
   15.10 Tapered dies ......................................... 238
   15.11 Drawing boxes ........................................ 240
   15.12 Residual stresses .................................... 241
   NOTES OF INTEREST .......................................... 242
   REFERENCES ................................................. 242
   PROBLEMS ................................................... 242
16 Forming Limit Diagrams ..................................... 245
   16.1 Localized necking ..................................... 245
   16.2 Forming limit diagrams ................................ 249
   16.3 Experimental determination of FLDs .................... 250
   16.4 Calculation of forming limit diagrams ................. 252
   16.5 Factors affecting forming limits ...................... 255
   16.6 Changing strain paths ................................. 258
   16.7 Stress-based forming limits ........................... 260
   NOTE OF INTEREST ........................................... 260
   REFERENCES ................................................. 261
   PROBLEMS ................................................... 261
17 Stamping ................................................... 263
   17.1 Stamping .............................................. 263
   17.2 Draw beads ............................................ 263
   17.3 Strain distribution ................................... 265
   17.4 Loose metal and wrinkling ............................. 266
   17.5 Springback ............................................ 268
   17.6 Strain signatures ..................................... 269
   17.7 Die design ............................................ 270
   17.8 Toughness and sheet tearing ........................... 272
   17.9 General observations .................................. 274
   NOTES OF INTEREST .......................................... 275
   REFERENCES ................................................. 275
   PROBLEMS ................................................... 275
18 Hydroforming ............................................... 277
   18.1 General ............................................... 277
   18.2 Free expansion of tubes ............................... 277
   18.3 Hydroforming into square cross sections ............... 279
   18.4 Bent sections ......................................... 281
   NOTE OF INTEREST ........................................... 283
   REFERENCES ................................................. 283
   PROBLEMS ................................................... 283
19 Other Sheet Forming Operations ............................. 285
   19.1  Roll forming ......................................... 285
   19.2 Spinning .............................................. 286
   19.3 Foldable shapes ....................................... 288
   19.4 Incremental sheet forming ............................. 288
   19.5 Shearing .............................................. 290
   19.6 Flanging, hole expansion, and beading ................. 291
   19.7 Hemming ............................................... 292
   NOTE OF INTEREST ........................................... 293
   REFERENCES ................................................. 293
   PROBLEMS ................................................... 293
20 Formability Tests .......................................... 294
   20.1 Cupping tests ......................................... 294
   20.2 LDH test .............................................. 294
   20.3 Post-uniform elongation ............................... 297
   20.4 OSU formabiiity test .................................. 297
   20.5 Hole expansion ........................................ 298
   20.6 Hydraulic bulge test .................................. 299
   20.7 Duncan friction test .................................. 300
   REFERENCES ................................................. 301
   PROBLEMS ................................................... 301
21 Sheet Metal Properties ..................................... 304
   21.1 Introduction .......................................... 304
   21.2 Surface appearance .................................... 305
   21.3 Strain aging .......................................... 305
   21.4 Roller leveling and temper rolling .................... 308
   21.5 Properties of steels .................................. 309
   21.6 Grades of low-carbon steel ............................ 309
   21.7 Tailor-welded blanks .................................. 314
   21.8 Special sheet steels .................................. 315
   21.9 Surface treatment ..................................... 315
   21.10 Stainless steels ..................................... 316
   21.11 Aluminum alloys ...................................... 317
   21.12 Copper and brass ..................................... 321
   21.13 Hexagonal close-packed metals ........................ 322
   21.14 Tooling .............................................. 323
   21.15 Product uniformity ................................... 323
   21.16 Scrap ................................................ 324
   NOTES OF INTEREST .......................................... 324
   REFERENCES ................................................. 325
   PROBLEMS ................................................... 325

Index ......................................................... 327


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