Cold Workability limits of Brass were studied as a function of friction, aspect ratio and specimen geometry. Five standard shapes of the axis symmetric specimens of cylindrical with aspect ratios 1.0 and 1.5, ring, tapered and flanged were selected for the present investigation. Specimens were deformed in compression between two flat platens to predict the metal flow at room temperature. The longitudinal and oblique cracks were obtained as the two major modes of surface fractures. Cylindrical and ring specimen shows the oblique surface crack while the tapered and flanged shows the longitudinal crack. Machine Vision system using PC based video recording with a CCD camera was used to analyze the deformation of 4 X 4 mm square grid marked at mid plane of the specimen. The strain paths obtained from different specimens exhibited nonlinearity from the beginning to the end of the strain path. The circumferential stress component O s increasingly becomes tensile with continued deformation. On the other hand the axial stress O z , increased in the very initial stages of deformation but started becoming less compressive immediately as barreling develops. The nature of hydrostatic stress on the rim of the flanged specimen was found to be tensile. Finite element software ANSYS has been applied for the analysis of the upset forming process. When the stress values obtained from finite element analysis were compared to the measurements of grids using Machine Vision system it was found that they were in close proximity.
KeywordsFrictionUpsettingVision SystemFinite Element Analysis
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