PROCESSES
Hot working and cold working of metals Forging processes
Open, impression and closed die forging Characteristics of
the process Types of Forging Machines Typical forging
operations Rolling of metals Types of Rolling mills - Flat
strip rolling Shape rolling operations Defects in rolled
parts - Principle of rod and wire drawing -Tube drawing
Principles of Extrusion Types of Extrusion Hot and Cold
extrusion Equipments used
COLD WORKING
Plastic deformation which is carried out within the recrystallization
temperature and over a time interval such that the strain hardening is
not relieved is called cold working.
Cold rolling
Cold forging
Cold extrusion
Bending
Drawing
Shearing
Disadvantages :
1.Ductility of metal is reduced.
2. Deformation energy required is high, so rugged and more powerful equipment
is required, thus equipment cost is high.
3. Severe stresses are set up, this requires stress relieving, which increases the
cost
4. Owing to limited ductility at room temperature, the complexity of shapes
that can be readily produced is limited.
5. Cold working, for large deformation, requires several stages with interstage
annealing which increases the production cost.
1) HOT WORKING
Rolling
Forging
Extrusion
Hot drawing
Pipe welding
Piercing
Disadvantages :
1. Handling of material is not so easy.
Cold Rolling
Hot Rolling
Extrusion
Drawing
Forging
Advantages of forging
Disadvantages of forging
1. Rapid oxidation in forging of metal surface at high temperature results
in scaling which wears the dies.
2. The close tolerances in forging operations are difficult to maintain.
3. Forging is limited to simple shapes and has limitation for parts having
undercuts etc.
4. Some materials are not readily worked by forging.
5. The initial cost of forging dies and the cost of their maintenance is
high.
6. The metals gets cracked or distorted if worked below a specified
temperature limit.
7. The maintenance cost of forging dies is also very high.
Drop forging hammer, fed by conveyor and heating units at the right of
the
Forging Presses
Apply gradual pressure to accomplish compression operation
Types:
Mechanical press - converts rotation of drive motor into
linear motion of ram
Hydraulic press - hydraulic piston actuates ram
formers
Upset Forging
Figure 19.23 Examples of heading (upset forging) operations: (a) heading a nail
using open dies, (b) round head formed by punch, (c) and (d) two common
head styles for screws formed by die, (e) carriage bolt head formed by punch
and die.
workpart
is
completely
Open-Die Forging
Part sizes may range from very small (the size of nails, pins, and bolts)
to very large (up to 23 m, long shafts for ship propellers)
Impression-Die Forging
In impression-die forging, the die surfaces contain a shape or
impression that is imparted to the work during compression, thus
constraining metal flow to a significant degree.
In this type of operation, a portion of the work metal flows beyond the
die impression to form flash, as shown in the figure.
Flash is excess metal that must be trimmed off later.
Impression-Die Forging
Impression-Die Forging
Flashless Forging
Flashless Forging
Figure 19.17 Flashless forging: (1) just before initial contact with workpiece,
(2) partial compression, and (3) final punch and die closure.
Extrusion
Compression forming process in which work metal is forced to
flow through a die opening to produce a desired
cross-sectional shape
Process is similar to squeezing toothpaste out of a toothpaste
tube
In general, extrusion is used to produce long parts of
uniform cross sections
Two basic types:
Direct extrusion
Indirect extrusion
Extrusion
Direct Extrusion
Direct extrusion.
(a) Direct extrusion to produce a hollow or semi-hollow cross sections; (b) hollow
and (c) semi-hollow cross sections.
Indirect Extrusion
Advantages of Extrusion
Bar Drawing
Accomplished as a single-draft operation - the stock is
pulled through one die opening
Beginning stock has large diameter and is a straight cylinder
Requires a batch type operation
Wire Drawing
Continuous drawing machines consisting of multiple draw
dies (typically 4 to 12) separated by accumulating drums
Each drum (capstan) provides proper force to draw wire
stock through upstream die
Each die provides a small reduction, so desired total
reduction is achieved by the series
Rolling
Deformation process in which work thickness is reduced
by compressive forces exerted by two opposing rolls
The Rolls
Rotating rolls perform two main functions:
Pull the work into the gap between them by friction
between workpart and rolls
Simultaneously squeeze the work to reduce its cross section
Types of Rolling
Based on workpiece geometry :
Flat rolling - used to reduce thickness of a
rectangular cross section
Shape rolling - square cross section is formed
into a shape such as an I-beam
Based on work temperature :
Side view of flat rolling, indicating before and after thicknesses, work
velocities, angle of contact with rolls, and other features.
Shape Rolling
Work is deformed into a contoured cross section rather than
flat (rectangular)
Accomplished by passing work through rolls that have the
reverse of desired shape
Products include:
Rolling Mills
Equipment is massive and expensive
Rolling mill configurations:
Two-high two opposing rolls
Three-high work passes through rolls in both directions
Four-high backing rolls support smaller work rolls
Figure 19.5 Various configurations of rolling mills: (b) 3-high rolling mill.
Figure 19.5 Various configurations of rolling mills: (c) four-high rolling mill.
Cluster Mill
Multiple backing rolls allow even smaller roll diameters
Figure 19.5 Various configurations of rolling mills: (e) tandem rolling mill.
Thread Rolling
Thread Rolling