Solid Processes

In this chapter, materials processing routes that involve the deformation of solid engineering materials are explored. The chapter begins with a fundamentals section that introduces the principles of deformation and plastic flow under uniaxial and triaxial stresses, and the typical mechanical responses of metals and thermoplastic polymers. The wire drawing process is covered in detail and analyzed using a forced balance (slab) method. This section reveals how sequential deformations lead to the final desired shape and how work hardening of the metal changes the process requirements. Extrusion, forging, and rolling are covered to show how different shapes are processed from solids, and the importance of hot working. The next section introduces several forming operations that begin with metal or plastic sheets, and the last section covers solid based additive manufacturing methods, focusing on those that employ friction.