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Metal Forming Processes
Metal Forming Processes
Practically all metals, which are not used in cast form are
Practically all metals, which are not used in cast form are
reduced to some standard shapes for subsequent processing.
reduced to some standard shapes for subsequent processing.
the
the
rolls cannot draw fresh strip
rolls cannot draw fresh strip
Roll torque, power etc. increase with increase in roll work
Roll torque, power etc. increase with increase in roll work
contact length or roll radius
contact length or roll radius
Pressure during rolling
Pressure during rolling
Typical pressure variation along
the contact length in flat rolling.
The peak pressure is located at
the neutral point. The area
beneath the curve, represents
roll force.
Friction in rolling: It depends on lubrication,
work material and also on the temperature. In
cold rolling the value of coefficient of friction
is around 0.1 and in warm working it is
around 0.2. In hot rolling it is around 0.4. In
hot rolling sticking friction condition is also
seen and then friction coefficient is observed
up to 0.7. In sticking the hot wok surface
adheres to roll and thus the central part of the
strip undergoes with a severe deformation.
Roll passes to get a 12 mm rod
Roll passes to get a 12 mm rod
from 100 x 100 mm billet
from 100 x 100 mm billet
Roll
Roll
configurations
configurations
in rolling mills
in rolling mills
Two
Two
-
-
high and three
high and three
-
-
high mills are generally
high mills are generally
used for initial and intermediate passes during
used for initial and intermediate passes during
hot rolling, while four
hot rolling, while four
-
-
high and cluster mills
high and cluster mills
are used for final passes.
are used for final passes.
Last two arrangements are preferred for cold
Last two arrangements are preferred for cold
rolling because roll in these configurations are
rolling because roll in these configurations are
supported by back
supported by back
-
-
up rolls which minimize
up rolls which minimize
the deflections and produce better tolerances.
the deflections and produce better tolerances.
Various Roll Configurations (a) Two Various Roll Configurations (a) Two- -high (b) Three high (b) Three- -high high
(c) Four (c) Four- -high (d) Cluster mill (e) Tandem mill high (d) Cluster mill (e) Tandem mill
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Other deformation processes related to rolling
Other deformation processes related to rolling
Forging
Forging
Forging is perhaps oldest metal working process and was
Forging is perhaps oldest metal working process and was
known even during prehistoric days when metallic tools
known even during prehistoric days when metallic tools
were made by heating and hammering.
were made by heating and hammering.
Forging is basically involves plastic deformation of
Forging is basically involves plastic deformation of
material between two dies to achieve desired
material between two dies to achieve desired
configuration. Depending upon complexity of the part
configuration. Depending upon complexity of the part
forging is carried out as
forging is carried out as
open die forging and closed die
open die forging and closed die
forging.
forging.
In open die forging, the metal is compressed by repeated
In open die forging, the metal is compressed by repeated
blows by a mechanical hammer and shape is manipulated
blows by a mechanical hammer and shape is manipulated
manually.
manually.
In closed die forging, the desired configuration is
In closed die forging, the desired configuration is
obtained by squeezing the
obtained by squeezing the
workpiece
workpiece
between two shaped
between two shaped
and closed dies.
and closed dies.
On squeezing the die cavity gets completely filled and
On squeezing the die cavity gets completely filled and
excess material comes out around the periphery of the
excess material comes out around the periphery of the
die as
die as
flash
flash
which is later trimmed.
which is later trimmed.
Press forging and drop forging are two popular
Press forging and drop forging are two popular
methods in closed die forging.
methods in closed die forging.
In press forging the metal is squeezed slowly by a
In press forging the metal is squeezed slowly by a
hydraulic or mechanical press and component is
hydraulic or mechanical press and component is
produced in a single closing of die, hence the
produced in a single closing of die, hence the
dimensional accuracy is much better than drop
dimensional accuracy is much better than drop
forging.
forging.
Both open and closed die forging processes are carried
Both open and closed die forging processes are carried
out in hot as well as in cold state.
out in hot as well as in cold state.
In forging
In forging
favorable grain orientation
favorable grain orientation
of metal is
of metal is
obtained
obtained
Open and closed die forging
Open and closed die forging
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Grain orientation in forging
Grain orientation in forging
Forging Machining
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Barreling in
Barreling in
forging
forging
Flash less forging or
Flash less forging or
precision forging
precision forging
Self reading in forging
Self reading in forging
Fullering
Fullering
Edging
Edging
Cogging
Cogging
Upsetting
Upsetting
Heading
Heading
Swaging
Swaging
Radial forging etc.
Radial forging etc.
Go through any book on
Manufacturing processes
by Kalpakjian, Groover
or Degarmo
Extrusion
Extrusion
It is a relatively new process and its commercial
It is a relatively new process and its commercial
exploitation started early in the nineteenth century with the
exploitation started early in the nineteenth century with the
extrusion of lead pipes. Extrusion of steels became
extrusion of lead pipes. Extrusion of steels became
possible only after 1930 when extrusion chambers could
possible only after 1930 when extrusion chambers could
be designed to withstand high temperature and pressure.
be designed to withstand high temperature and pressure.
In extrusion, the material is compressed in a chamber and
In extrusion, the material is compressed in a chamber and
the deformed material is forced to flow through the die.
the deformed material is forced to flow through the die.
The die opening corresponds to the cross section of the
The die opening corresponds to the cross section of the
required product.
required product.
It is basically a hot working process, however, for softer
It is basically a hot working process, however, for softer
materials cold extrusion is also performed.
materials cold extrusion is also performed.
Direct and Indirect Extrusion
Direct and Indirect Extrusion
In direct extrusion metal flows in the In direct extrusion metal flows in the
same direction as that of the ram. same direction as that of the ram.
Because of the relative motion between Because of the relative motion between
the heated billet and the chamber walls, the heated billet and the chamber walls,
friction is severe and is reduced by using friction is severe and is reduced by using
molten glass as a lubricant in case of molten glass as a lubricant in case of
steels at higher temperatures. At lower steels at higher temperatures. At lower
temperatures, oils with graphite powder temperatures, oils with graphite powder
is used for lubrication. is used for lubrication.
s
s
book)
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Defects in Rolling
Defects in Rolling
Defects in forging
Defects in forging
Defects in extrusion
Defects in extrusion
Surface cracking Surface cracking
piping piping
Internal cracking Internal cracking