Ringkasan Materi Kuliah Minggu-9

ROLLING AND FORGING

Schematic outline of various flat-rolling and shape-rolling processes.

Source: After the American Iron and Steel Institute.

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(1)Rolling
Deformation process in which work thickness is reduced by compressive
forces exerted by two opposing rolls

Increase in strip width (spreading) in flat rolling. Note that similar

spreading can be observed when dough is rolled with a rolling pin.

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

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Effects of Hot Rolling

Changes in the grain structure of cast or of large-grain wrought metals

during hot rolling. Hot rolling is an effective way to reduce grain size in
metals for improved strength and ductility. Cast structures of ingots or
continuous castings are converted to a wrought structure by hot
working.

Production of Steel Balls

(a) Production of steel balls by the skew-rolling process.

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(b) Production of steel balls by upsetting a cylindrical blank. Note the
formation of flash.

The balls made by these processes subsequently are ground and

polished for use in ball bearings.

Thread-Rolling Processes

Bulk deformation process used to form threads on cylindrical parts by

rolling them between two dies

Thread rolling with flat dies: (1) start of cycle, and (2) end of cycle.

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 Thread-rolling processes: (a) and (c) reciprocating flat dies; (b) two-
roller dies. (d) Threaded fasteners, such as bolts, are made
economically by these processes at high rates of production. Source:
Courtesy of Central Rolled Thread Die Co.

Machined and Rolled Threads

(a) Features of a machined Grain flow in (b) machined and (c) rolled
or rolled thread threads

Unlike machining, which cuts through the grains of the metal, the
rolling of threads imparts improved strength because of cold working
and favorable grain flow.

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(2)Forging
Microstructure as a Function of Manufacturing Method

Schematic illustration of a part made by three different processes

showing grain flow. (a) Casting by the processes described in Chapter
11. (b) Machining form a blank, described in Part IV of this book, and
(c) forging. Each process has its own advantages and limitations
regarding external and internal characteristics, material properties,
dimensional accuracy, surface finish, and the economics of production.
Source: Courtesy of Forging Industry Association.

Grain Flow in Forging

A pierced round billet showing grain-flow pattern (see also Fig 14.12c).
Source: Courtesy of Ladish Co., Inc.

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Heading

(a) Heading operation to form heads on fasteners, such as nails and

rivets. (b) Sequence of operations to produce a typical bolt head by
heading.