ADVANCED FORMING

TECHNIQUES

Dr. Ibraheem Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department
•The most general state of stress at a point may
be represented by 6 components,

 x , y , z normal stresses
 xy ,  yz ,  zx shearing stresses
(Note :  xy   yx ,  yz   zy ,  zx   xz )

•Same state of stress is represented by a different

set of components if axes are rotated.

•The first part of the chapter is concerned with

how the components of stress are transformed
under a rotation of the coordinate axes. The
second part of the chapter is devoted to a similar
analysis of the transformation of the components
of strain.

Dr. Ibrahim Sabry

Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

• Plane Stress - state of stress in which two faces of

the cubic element are free of stress. For the
illustrated example, the state of stress is defined by
 x ,  y ,  xy and  z   zx   zy  0.

• State of plane stress occurs in a thin plate subjected

to forces acting in the midplane of the plate.

• State of plane stress also occurs on the free surface

of a structural element or machine component, i.e.,
at any point of the surface not subjected to an
external force.

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department
Example 1 SOLUTION:
• Find the element orientation for the principal
stresses from
2 xy
tan 2 p 
 x  y

For the state of plane stress • Determine the principal stresses from
2
shown, determine (a) the x  y  x   y  2
 max,min       xy
principal planes, (b) the 2  2 
principal stresses, (c) the
maximum shearing stress and • Calculate the maximum shearing stress with
the corresponding normal 2
stress.   x   y  2
 max      xy
 2 
x  y
 
2
Dr. Ibrahim Sabry
Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

SOLUTION:
• Find the element orientation for the principal
stresses from
2 xy 2 40 
tan 2 p    1.333
 x  y 50   10 
2 p  53.1, 233.1

 x   50 MPa  xy   40 MPa  p  26.6, 116.6

 x   10 MPa
• Determine the principal stresses from
2
x  y  x  y  2
 max,min       xy
2  2 
 20  302  402
 max  70 MPa
 min  30 MPa

Dr. Ibrahim Sabry

Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

• Calculate the maximum shearing stress with

2
 x  y  2
 max      xy
 2 
 302  402
 max  50 MPa
 x  50 MPa  xy  40 MPa
 s   p  45
 x  10 MPa
 s  18.4, 71.6

• The corresponding normal stress is

 x   y 50  10

   ave  
2 2
   20 MPa

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Example :- A thin-wall tube with closed ends is subjected to a

maximum internal pressure of 35 MPa in service. The mean
radius of the tube is 30 cm.
(a) If the tensile yield strength is 700 MPa, what minimum
thickness must be specified to prevent yielding?
(b) If the material has a yield strength in shear of k = 280
MPa, what minimum thickness must be specified to prevent
yielding?

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry

Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

A circle 1 cm diameter was printed on a sheet of metal prior to

a complex
stamping operation. After the stamping, it was found that the circle had
become an ellipse with major and minor diameters of 1.300 and 1.100 cm.
a) Determine the effective strain.
b) If a condition of plane stress (σ3 = 0) existed during the
stamping, and the ratio α= σ2/σ1 remained constant,
what ratio σ1/ must have existed?

Dr. Ibrahim Sabry

 Modern Academy Chapter 1: Introduction to metal forming processes
MNF530 , Mechanical design and production technology Department

Dr. Ibrahim Sabry