A cylindrical 4135 cold-rolled steel workpiece has an upsetting load applied at room temperature using an open-die forging with flat dies to a new height, ha = 50 mm, as shown below. The initial diameter is do = 220 mm, the initial height is ho = 180 mm. 4135 cold-rolled MPa=1100 Psi= 16000 Strain hardening exponent, n = 0.14 A) What is the diameter of the forging at the end of the forging stroke? B) What is the longitudinal true strain of the forging at the end of the forging stroke? C) What is the true (flow) stress required in the material at the end of the forging stroke? D) Using the average pressure formula, what is the corresponding coefficient of friction if the upsetting force at the end of the stroke is 170 MN?

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Forming and Shaping

Metal forming is a category of metalworking process through which the material can be given the desired shape and size by subjecting it to plastic deformation, where the component undergoes bulk deformation process upon application of loads. Unlike the shearing and machining process, the material does not undergo up to a failure point as indicated in the stress-strain curve. Hence, the stresses induced during the forming process are greater than yield strength but less than the failure strength of the material. The process does not lead to the loss of material, so it can be said to be an economical process. During forming, the material is subjected to tensile forces, compressive forces, bending, and shearing loading conditions. The material should possess the property of ductility to undergo the forming process.