Effect of Contact Pressure on Strain Distribution during Compression-Type Bulk Forming Processes

Inhomogeneity of the material properties of workpieces developed during compression-type bulk forming processes (CBFPs) is an important issue. The effect of contact pressure on the workpiece surface on the strain inhomogeneity in the workpiece was investigated to understand and reduce the formation of strain inhomogeneity during CBFPs. Workpieces fabricated via rod caliber rolling, rod flat rolling, plate flat rolling, and rod compression were analyzed and compared. The extent of strain inhomogeneity in a workpiece differs with the forming process, because the occurrence of macroscopic shear bands (MSBs) is dependent on the workpiece shape and tool design. A flat-rolled rod exhibits the maximum strain inhomogeneity, whereas a flat-rolled plate shows the minimum strain inhomogeneity. The occurrence of MSBs was influenced by the distribution of the normal contact pressure or compression stress. The MSBs were stronger when the contact pressure was higher in the edge region of the surface. For example, the flat-rolled plate exhibited weak MSBs due to the relatively uniform or higher contact pressure on the central region. In contrast, strong MSBs appeared in the flat-rolled rod and compressed rod, because the contact pressure in the edge region of these two processes was high. Thus, the strain inhomogeneity in a workpiece fabricated via CBFPs can be reduced by controlling the contact pressure distribution on the workpiece surface.