Theory of Plasticity

Definition of Stress and Strain. Shear and normal stress, Elastic versus Plastic Deformation. Definition
of the State of Stress at a Point, tensor of stress and strain, deviatoric state of stress, mean stress,
invariants. Micro mechanism of plastic deformation.
Engineering and true stress-strain diagram. Engineering stress, tension and compression tests.
Stress-strain diagram. Idealized stress-strain curves and their empirical equations, reologic models,
mathematical material models,
. Yield criteria, assumptions. Maximum Shear Stress or Tresca Criterion. Sen Wenan Criterion von
Mises Criterion. Effective plastic strain.. The Yield Surface, Strainhardening.
Laws of conservation and their conclusions in continuum mechanic. Energy and work determination.
General approach (using of equilibrium and motion equations), dissipation and velocity functions, using of th e
stress-strain dyagramm.
Approximate methods for analysis of plastic deformation. Upper bound methods. Sleep line methods
Finite element method. EM in solution of the plastic problem. Fundamentals of FEM Analysis.
Computer-aided approach-process modelling. Modeling of the material flow in specialized software
SuperForge, Deform

Metalworking processes

Heating of metal before PMW. Temperature interval of heat treatment. Types of heating and heat
treatment. Processes of metal heating before plastic deformation and their comparison. Classification of
heat treatment.
Equipment for plastic metal working of metals. Classification of the equipment for plastic metal
working. Forging and die-forging hammers, their basic characteristics. Counterblow hammers. Presses,
their basic characteristics. Specialised press-forging equipment.
Classification principles of the metalworking processes. Classification of the metalworking
processes.
Extrusion. Classification, main parameters, typical defects, extrusion practice, hot extrusion, die
design and materials, lubrication, cold extrusion, impact and hydrostatic extrusion.
Open-die forging. Application, advantages. Basic blacksmith operations. Upsetting. Barreling.
Cogging, drawing out, breaking dawn. Bending. Piercing and punching. Main and auxiliary tooling fore
open die forging.
Design of a forging. Main stages of open die forging process design. Allowances, tolerances and
flooding. Determination of volume and optimum sizes of initial stock. A choice of a type and sequence of
the main open-die operations. Selection of the equipment for open-die stock forging.
Typical sequence of the forging process. Related, auxiliary, preliminary, intermediate and finishing
operation. Method of stock production.
Close-die forging. Application and main characteristics of close-die forging.Classification of closed die
forging. Comparison of the open-die and close-die forging.
Design of die-forged forging. Choice of parting plane. Die-forging draft, edge and fillet radiuses of
the sharp. Flash at close-die forging and its function.
Flashless forging, classification, advantages, disadvantages, tooling, practice, application.
Multiple-stage (multiimpresson) close-die forging. Classification of impression. Determination of a
quantity and types of preliminary impressions needed for realisation of multiple- stage close-die forging.
Cross section mass distribution diagram. Location of impressions. Design of the closed die.
Material used for forging.
Auxiliary and related metalworking processes. Typical forging processes sequence.
Forging defects, geometrical and material induced defects
Friction in metalworking processes. Types of a friction. Factors influencing friction parameter.
Friction influence on forging operations. Lubricants, classification, their importance and
requirements