During a hot upset forging process the starting diameter of work part is 36 mm, and starting height is 66 mm. The work part is upset by open die to diameter 70 mm. The strength coefficient of work metal is 45 MPa, and coefficient of friction between die and work interface is 0.2. Determine (a) Final height of the work part, (b) maximum force in the process.

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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.