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Definition:
Rolling is the most widely used forming process, which provides high production and close
control of final product.
The metal is subjected to high compressive stresses as a result of the friction between the
rolls and the rolling process metal surface.
Terminology
Bloom is the product of first breakdown of ingot
(cross sectional area > 230 cm2).
Billet is the product obtained from a further reduction by hot rolling
(cross sectional area > 40x40 mm2).
Slab is the hot rolled ingot
Plate is the product with a thickness > 6 mm.
Sheet is the product with a thickness < 6 mm and width > 600 mm.
Strip is the product with a thickness < 6 mm and width < 600 mm
(cross sectional area > 100 cm2 and with a width ≥ 2 x thickness).
Types:
Hot rolling
Breakdown of ingots into blooms and billets is generally done by hot-rolling. This is
followed by further hot-rolling into plate, sheet, rod, bar, pipe, rail.
Cold rolling
The cold-rolling of metals has played a major role in industry by providing sheet, strip, foil
with good surface finishes and increased mechanical strength with close control of product
dimensions.
Typical arrangement of rollers for rolling mill:
-diame
Two-high mill, pullover
The work can be passed back and forth through the rolls by reversing their direction of
rotation. Three-high mill consist of upper and lower driven rolls and a middle roll, which rotates by
friction.
Four-high mill
Consist of upper and lower driven rolls and a middle roll, which rotates by friction.
Four-high mill
Small-diameter rolls (less strength & rigidity) are supported by larger-diameter backup rolls.
ch
rotates by friction.
Continuous rolling
M
Planetary mill s s
Consist of a pair of heavy backing rolls surrounded by a large number of planetary rolls.
Each planetary roll gives an almost constant reduction to the slab as it sweeps out a circular
path between the backing rolls and the slab.
As each pair of planetary rolls ceases to have contact with the work piece, another pair of
rolls makes contact and repeat that reduction.
The overall reduction is the summation of a series of small reductions by each pair of rolls.
Therefore, the planetary mill can hot reduces a slab directly to strip in one pass through the
mill.
The operation requires feed rolls to introduce the slab into the mill, and a pair of planishing
rolls on two backing rolls.
Ex. No: 2 Determination of strain hardening exponent
Aim:
Apparatus:
Procedure:
Formula:
Volume constancy principle,
AoHo=AiHi
Where,
Ao = Area of the cross section of the disc before deformation.
H0 = Thickness of the disc before deformation.
Ai = Area of the cross section of the disc after deformation.
hi = thickness of the disc after deformation.
ε = True strain
Result:
The strain rate sensitivity index for the given material is found.
Ex. No: 3 Determination of strain rate sensitivity index
Aim:
Apparatus:
Procedure:
Formula:
Volume constancy principle,
AoHo=AiHi
Where,
Ao = Area of the cross section of the disc before deformation.
H0 = Thickness of the disc before deformation.
Ai = Area of the cross section of the disc after deformation.
hi = thickness of the disc after deformation.
ε = True strain
Result:
The strain rate sensitivity index for the given material is found.
Ex No: 4 Study The Methods To Get Forming Limit Diagram From
Experimental Data.
AIM: Study The Methods To Get Forming Limit Diagram From Experimental Data.
OBJECTIVES:
A forming limit diagram, also known as a forming limit curve, is used in sheet metal forming for
predictingforming behavior of sheet metal.After performing this experiment, the students will be
able to:
Understand the Forming limit Diagram (FLD) and Forming limit curve (FLC).
THEORY:
1) FORMING LIMIT DIAGRAM:
Forming limit diagrams (FLD’s) offer a convenient and useful tool in sheet products manufacturing
analysis. They show the critical combinations of major strain and minor strain in the sheet surface at
the onset of necking failure.Formability in the context of multiple phase operations strongly depends
of the deformation history and thereforedemands an investigation of every particular case.
Thismakes the experimental determination of FLD’s unappreciativeexpensive and causes the
necessity to develop an accurateand efficient theoretical method for formability prediction.
The basic concept of the FLD was first introduced by Keeler and Backofen, who developed the right
hand side of the FLD. Goodwin extended this diagram to the left hand side. Fig. 1 illustrates the
FLD which is divided into two regions separated by a curve, the forming limit curve (FLC). The
region below the FLC corresponds to safe strain states whereas that above the FLC represents failure
strain states. Even though the strain states of the sheet metal forming processes are complex, FLDs
are often constructed using tensile and biaxial stretch tests.
The diagram attempts to provide a graphical description of material failure tests, such as a
punched dome test.In order to determine whether a given region has failed, a mechanical test is
performed. The mechanical test is performed by placing a circular mark on the workpiece prior to
deformation, and then measuring the post-deformation ellipse that is generated from the action on
this circle. By repeating the mechanical test to generate a range of stress states, the formability limit
diagram can be generated as a line at which failure is onset.
2) METHODS TO GET FORMING LIMIT DIAGRAM:
As the use of the FLD is widely developed in the sheet metal forming industry, different
experimental methods have been proposed. The various methods to get Forming Limit Diagram
(FLD) are:
1. ASTM standard test method.
5. DIC-Grid method.
Among this, the ASTM standard test, has received the greatest attention. In this method, a
hemispherical punch is used to deform a sheet while a lock bead prevents material flowing from
outside to inside the die. After fracture occurs, the length changes of a grid that was printed on the
sheet surface are measured. The major and minor strains located nearest to the fractured line define
the FLD at localized necking. By changing the width of the sheet specimens while maintaining the
length different strain paths defined by r ¼ de2=de1, can be investigated. Thus, mostregions of
interest in the FLD can be obtained using one hemispherical punch and one set of tools. This test has
become thestandardmethodASTME2218-2 for determining FLDs. However, whileASTME2218-
2appliestosheetthicknessesranging from0.5to3.3mm, no standard methods have been developed
forsheetmaterialswiththicknessbelow0.5mm.Inspite of this lack of standards, several attempts were
made to determine theFLDofsheetmaterialsthinnerthan0.5mm.
Using the hydraulic bulgetest, Diehlet al. obtained the FLD soffine grained Se–Cu58and
99.5% pure aluminum sheets with thicknesses as low as 25mm. In this method, thin sheet so foils
were subjected to biaxial stretching using one circular and two elliptical shaped die openings. The
different as pectratios of the die openings permitted to obtain different biaxial strain states.
Mahmudi used the same approach for AA8014 aluminum alloy sheet sasthin as 45mm. FLDs
were determined with this technique byothers, even for sheet materials thicker than 0.5mm.
However, this test method is unable to determine the left hand side of the FLD, including plane
strain, which is a major deficiency.
The Marciniak test is schematically illustrated in Fig 2. When a specimen blank formed directly over a
punch circumferential fracture occurs a long the punch shoulder. This can be eliminated with the use of a
washer. In addition, the hole in the center of the was her assures free expansion of the specimen blank.
This condition induces fracture of the specimen blank in its central area. This can be clearly understood
by analyzing the material flow depicted in Fig 3. As the punch moves up, the two sheet materials will
flow in the outward directions. In this test, lubricant is applied only between the punch and the washer,
but not between the washer and the specimen blank. Therefore, the outward flow of the washer produces
an additional friction force to the specimen blank. This leads to strain concentration and ultimate fracture
in the center region of the specimen blank no tin contact with the washer. The recessed area in the central
portion of the punch assists the minimization of friction between the punch and the washer. In this test, in
order to conduct successful tests, the washer mustexhibit higher formability than the specimen blank, and
the diameter of the hole must be selected properly. When this test was conducted for the first time by
Marciniak and Kuczyn´ ski, the washer did not have a hole. This test was markedly improved with the
introduction of a circular hole in the washer to allow free expansion of the specimen blank and the use of
two elliptical punches with different aspect ratios to enable different strain paths. In subsequentde cades,
several researchers used the Marciniak test with significant modifications.
Tadrosand Mellor conducted the modified Marciniak tests to determine the right hand side of the
FLD for steel, aluminum alloy and brass , and also to investigate the influence of the surface roughness
development on the FLC. Kleemola and Kumpulainen determined the entire range of the FLD using
sheet strips having different widths to obtain different strain paths as in the ASTM standard test. There
were other proposals for further modifications, al be it of minor nature. The Marciniak test was also used
to determine the FLD of a magnesium alloy at high temperature. This study showed that the flat surface
in the Marciniak test leads to a uniform temperature distribution in the specimen.
A new method for determining the forming limit diagram(FLD) of thin sheet metals, called DIC-
Grid method, is proposed based on digital image correlation (DIC) technique. It's assumed that there
exists one virtual grid with an initial diameter of 2.5mm, which is usually the same dimension as the grid
in traditional circular gridan alysis, close to the crack of specimen, and the limit strain point on FLD is
determined by the deformation of this virtual grid. The DIC-Grid method has been compared with
traditional circular grid analysis and the standard ISO/FDIS 12004-2 in Nakajima tests. The results show
that the forming limit strains obtained by the newly proposed method are more stable and precise.
Furthermore, DIC-Grid method can avoid the measurement error which exists in the circular grid
analysis. Meanwhile, it overcomes the shortcomings of time-consuming data processing and non-
applicable for unrealistic strain distribution in the method of ISO standard. In addition, the effect of the
ratio betweenDIC frame rate and the punch velocity on the determination of forming limit strains is
studied, and the minimum value of this ratio is suggested.
CONCLUSION:
In this way, we have studied the different methods to get the Forming limit diagram (FLD).
Ex No: 5 Determination of efficiency in water hammer forming
Aim:
Appartus:
Circular grids are formed over the sheet metal with the radius of 10,20,30, and 40mm.
The thickness along this line at all the grid points is measured
The blank is clamped with position in the water hammer forming appartus.
150 ml of water is filled with the die cylinder. The height of the water column is measured
.
The rope is then released instantaneously to make the weight to fall freely over the
floating plunger.
The experiment is repeated by varying the height of fall in steps of 500mm and five sets of
reading are tabulated.
From the formed blank, the polar height is measured by vernier height gauge and the
thickness of the blank after deformation is measured at all the grid points.the deformation
of grid is measured along diameter by using thread.
Formula:
пAet(t+n) ∑t(ra2-rb2)
0 η =
Energy input
where,
t = initial thickness off the meatl sheets ,mm
ra = radius after deformation, mm
rb = radius before deformation , mm
A&N = material constant.
For Al: A = 600N/mm2 , n = 0.16
Polar srain = ln (to / tp)
where,
TO = original thickness of the sheet, mm
Tp = Polar height of the sheet, mm
Average strain (et) = ∑ ln (to / tp) /N
Where,
N= no of grids
Graph:
Height of fall Vs. polar height
Height of fall Vs efficiency
Height of fall Vs. polar strain
Result:
The efficiency of water hammer forming is determined by water hammer apparatus
EX NO: 6
AIM:
To perform sheet metal forming in a hydraulic press and hence find out the average starin
after forming.
APPRATUS REQUIRED:
Sheet metal
Steel rule
Dial gauge
Hydraulic press
THEORY:
Sheet metal can be formed in many ways. Forming with help of hydraulic press is one of the
ways. In a hydraulic press, the basic principle involved in its working is Pascal’s Law.
Pascal’s Law:
It states that pressure is equal in all direction in space in any liquid. It is valid to:
The hydraulic press consists of two dies based on our requirement either top die or bottom
die is made to move up or down, the hydraulic press can also be automated and can be used for mass
production.
FORMULA:
The specimen is placed on the die , so that grid pattern forms the outer surface of the cup
Ram space is adjusted to an optimum speed. This is to overcome the fracture of the
specimen during forming
The specimen is placed on the die and the ram is allowed to move forward.
The time for which the ram is in contact with the blank is allowed adjusted.
Then the specimen is taken and increases in length of each grid were measured.
RESULT:
Thus the sheet metal operation on hydraulic press is conducted and its average strain is found
out.
Apparatus
hydraulic press
Dies
Dial gauge
Vernier calipers
Specimen
Description
Extrusion process is characterized as a solid material, one-dimensional forming process with
compressive state of stresses. In extrusion, a work-piece (billet) of cylindrical shape is placed in
closed container. The closed container has an orifice (extrusion die) and extrusion punch, that forces
the material toward the extrusion die orifice, see Fig. Two distinguished techniques are commonly
used in extrusion, namely; forward and backward extrusions.
Extrusion Processes:
The two commonly used extrusion techniques, direct (forward) and indirect (backward)
extrusion.. In direct extrusion, punch-displacement is equal to the extruded product displacement
both in magnitude and direction, while; the punch has an opposite displacement direction, compared
to the extruded product displacement in case of indirect process. Furthermore, hollow ram or punch
is used in case of indirect extrusion, while solid ram is used in case of direct extrusion. Load
capacity is larger in case of direct extrusion when compared with indirect extrusion process.
Procedure
Direct Extrusion:
1. The metal billet is placed in a container and driven through the die by the ram.
2. The dummy block or pressure plate is placed at the end of the ram in contact with the billet.
3. Friction is at the die and container wall requires higher pressure than indirect extrusion.
Indirect Extrusion:
1. The hollow ram containing the die is kept stationary and the container with the billet is caused to
move.
2. Friction at the die only (no relative movement at the container wall) requires roughly constant
pressure.
Formulae used
Result:
Apparatus
UTM
Dies
Dial gauge
Vernier calipers
Specimen
Procedure
Experimental tests were conducted to determine the dual friction factor map of the
aforementioned lubricants for material UNS A96082 under specific forming conditions. Accordingly,
experimental compression tests were realized using rings treated with the lubricants presented; for
this purpose, the universal test machine HOYTOM HM-100kN and flat platens as forming tools g
tools.
To conduct the RCTs, each ring was placed on the bottom plate of the test machine
(compression area) after lubrication of the contact surfaces; then, the top plate was positioned
making contact with the upper surface of the ring. Once contact was made, an increment of the load
was applied causing a reduction in height and the deformation of the inner radius. According to the
alternative approach presented in this paper, the lubricant was only applied at the first stage, as
explained previously.
The RCTs were conducted on three different rings for each lubricant in order to generate
enough points to create the friction map. Compressions were applied to reach loads of 30, 50, and 70
kN. The ram velocity of the upper plate of the test machine was 2.5 mm/s in all of the cases. The
conditions of the process.
Temperature Ram velocity 1st Stage Load 1st Stage Load 1st Stage Load 1st Stage Load
(C) (kN) (kN) (kN) (kN)
Mm/min
Result
AIM:
APPARATUS REQUIRED:
PROCEDURE:
Thus the design of single acting cylinder circuit was done and observed the working successfully
Ex No: 8(B) Simulation of basic double acting cylinder circuits
AIM:
APPARATUS REQUIRED:
PROCEDURE:
Thus the design of double acting cylinder circuit was done and observed the working successfully
Ex No: 9 Simulation of Hydraulic circuits
AIM:
APPARATUS REQUIRED:
PROCEDURE:
Thus the design of Hydraulic circuits was done and observed the working successfully
Ex No: 10 Simulation Of Electro Pneumatic Circuits
AIM:
To design the electro pneumatic sequencing circuits using electro pneumatic trainer kit.
APPARATUS REQUIRED:
PROCEDURE:
Thus the design of Electro Pneumatic sequencing circuits was done using electro pneumatic trainer
kit and observed the working successfully
Ex No: 11 Simulation Of Electro Hydraulic Circuits
AIM:
To design the electro hydraulic sequencing circuits using electro hydraulic trainer kit.
APPARATUS REQUIRED:
Hydraulic Reservoir
PROCEDURE:
Thus the design of Electro hydraulic sequencing circuits was done using electro hydraulic trainer kit
and observed the working successfully
Ex No:12 (a) PLC control of single acting cylinder using AND logic
AIM
APPARATUS REQUIRED
PROCEDURE
Provide +24V and -24V from PLC trainer to electro pneumatic with PLC panal
Output of the PLC (Q1) is direct connect to input of 3/2 single solenoid coil
Run the PLC.when two input (1i,2i) is high, this output is high.
TRUTH TABLE
INPUT OUTPUT
1i 2i 1Q
OFF OFF OFF
ON ON ON
ON OFF OFF
OFF ON OFF
RESULT:
Thus the actuation of single acting cylinder with AND gate was done successfully
Ex No: 12 (b) PLC control of single acting cylinder using OR logic
AIM:
To simulate the single acting cylinder with ORGATE using PLC ladder diagram.
APPARATUS REQUIRED:
PROCEDURE
Provide +24V and -24V from PLC trainer to electro pneumatic with PLC panal
Output of the PLC (Q1) is direct connect to input of 3/2 single solenoid coil
Run the PLC.when two input (1i,2i) is high, this output is high.
TRUTH TABLE
INPUT OUTPUT
1i 2i 1Q
OFF OFF OFF
ON ON ON
ON OFF ON
OFF ON ON
RESULT:
Thus the actuation of single acting cylinder with OR gate was done.
EX NO: 13 Simulation of Pneumatic circuits using automation studio
AIM:
APPARATUS REQUIRED:
PROCEDURE:
Thus the design the pneumatic circuits using automation studio using was done.