R. Wertheim Technion – Israel IWU.Fraunhofer - Germany Introduction to Deformation Processes

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany Shaping and Forming - Rough Shapes V o V f h o h f F F N Die Angle Dead Metal Zone Die Extrusion Drawing Forging Rolling

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany Tooling: Design and geometry Surface Finish Mechanical hardness Interface Conditions Coulomb ’ s law Equipment Accuracy and rigidity Rate of production Mechanics of Deformation Constitutive equation Thermal condition Rate Material FlowWorkpiece Final product

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany Material is incompressible, volume is constant  1+  2+  3=0

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany Yielding Criteria: when does material start to plastically deform? Tresca

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany Plane -Strain Compression

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany עירגול Rolling Technion

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany ערגולRolling Iscar 2001 Technion

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany The model reproduces one of Leonardo' s drawings. The two cylinders, by revolving, can level out a sheet of tin about 30 cm wide.

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany Hot Rolling and Microstructure Development

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany w L zz yy

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany V0V0 VfVf VrVr 

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany 

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany Hot Rolling Advantages –Stresses lower –Forces smaller –Power requirements less –No work hardening –Large deformations possible –Breaks up the cast structure into preferable forms –Closes porosity Disadvantages –Higher friction –Rolls need to be cooled –Material handling difficult

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany Cold Rolling Advantages –Deformations of ~ 50 to 80% –Work hardening increases strength –Excellent surface finish –Excellent tolerance on thickness and shape Disadvantages –High forces –Small reductions give rise to surface stresses and non- uniform stress distributions

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany The forces result from the resistance of the material to deformation and cause Roll bending –Non flat material Cambered sheet Buckling Roll flattening –Poor tolerances –Increased forces (larger contact area) Effect of Roll Forces

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany –Can decrease Roll Forces by: Reducing friction - Lubricants Using smaller diameter rolls Smaller reductions per pass (Residual stresses) Increasing temperature front or back tension camber rolls to compensate bend rolls back Roll Force Compensation

R. Wertheim Technion – Israel IWU.Fraunhofer - Germany Tolerance –Thickness Operator skill/automation –Gauges measure thickness of input and output –Computers control roll gap –Camber Roll bending/automation –Special segmented tension meters measure "shape" –Computers bend the rolls Surface finish –Roll finish Control of Overall Properties Bearing reaction forces Applied forces