° Metal Posrsing :> ———_} (+< 5mm] Bulk feaming, sheet Metal foxmnin 4: Rolling +. Punching / Blanking 2. Fooging. 2+ Deep dyavoing 3 Drawing 3- Strech fowming. 4 Extousion 4 Bending, )s w)t of Blase sae + High Gneway sare fori Elastic : S/min REN aoe or [min oN a sexe Shes tool min low wen S0/min oe Ho Llomon Equation _ ocmed om: Strain Howclen! n Exponenk € Figs AL Room temperatune.Elastic yy 4 Yield Roose PEraxUne Recovery. E Stress a Bo5c (®t) ~~ eo8e K= Stoength coetiient E= tee Atvain - {EY © g Kip 2 Te 3 7 EE Mecnomicat Propertes appearing in Seen strain diagram Uke yleld Strength , uLtimate tensile Aivengin omd Yok Clongation depends upon wate of deformation, C Strain wate)Ao? Tnitiat axea lo Thitial Area Length A Instantaneays Area L > Tnstantaneow @ Length > nga: Steain= AL L w ety Aloe ye] ©? Tuesteain ® te Te oT Engg. Stress ( OL= Taue stress go c= Fla Aolo= AL - Pos kb zg Khe Re ) 4D <> 43 @ 2 @ @ oD : y : GQ Delenmine engineering. Beran , true train, 7. elongation, 02~ +1 Redusckion iin Area. ° for Rod which Ls double in Lengto ‘o e lye alo > Alo Bo= Ag &g ‘ dt - AO =9 ® ex aioe OL GT AE e ° a [eet f. Reduetion in Area = Ron AF =(-3 x00 { €= mn (ire) i = 50/7: 6 ° ee J. elongounon =190%Ques 4/08! P-289 a=" = +01 é 2n(I t35) = org cess EF GBP 0-0997. 4 Qua {9/108/P-285 d= (28mm Ce= 460m Po CS d= |0'tmm H=2 €= Ln (2) &= 2 fn (18) = 0-358 e= Mn(ire) C= oudio Ope WB 460K 11-4310 re At Max load at UTS G@DNecs Formalin Ns € = Toue strain Ly skvain Hondemuing exponent‘Ques 16-/o8-/P- 299 59999980 88SS 6S6666C50" uTs= soomla espa 257- SE = YOOXVBS = S40 E= Lite) = 0-30 Quy. -25/to 8] 7-291 oe $020 e Ao = 10omm> oy = lor0 X C4) és Jn (2) Ag OY= on Cag) GE n og= ke Ea K(038°= 540 k= 774'92mPa p1smpPoQue-26/ 08/23 Oe S00 ol E=05 S00 a= loomfa Ex= 200fq KEE ay ' | 2 Ose os 3e pec Ac = Series® = 200X Id" Es ~ ‘os-e€s+ Hot & cold usooking Tempenotune 7 CRe) > (03-05) Tm Ctm > metting temp] | Re BOS tt kewin Cx) ‘VFox Taon For Lead '- gos =a T= 1539°C R= 0-5 (16394243) g06 k= 633°C Recrystaut Re =O: 5 (3254213) 299 ———— RO Grain Boundary Area In wonking Temp. CK) Melting Temp. Ci) . Recaystarization Tem? > Te isammnimun eroperatune te nen eats Re aystalie— ~akiono€ cold essuked metal occuss arithin a specified tin Te is armmimam temp. oe ystiidh NDS BY Stas begin-te fon Such tac ciss jocation censity grain Boundosues usu die out vndex the auion OF Heak and extemal force the old grains r aur disinigrare inxo Smots Size stocin Free Grains.1s known An gDUOBOOUOYIYUSY VV VY PYYYV NUYS 7As theguaims defsomation Pooceeds greater wesistamce tp the moment of the gaains nesultd in increase Handness omd Steg. » knoumas Atal Hordeming. Or w0sds Tandewring. Q Fora given Materior Homo Bove . ogous temp. 8 0: and Men Fing Working temp. G See Looxking temp WW= *O-BX 1043 EB ooour 585.4% 6 HOt Working <-> Cstrcuin Randerning Not fosioley] e Reenverd goaingaowe ism > Receystalizalion ondeform Greaing ed deformed Gyaine * Old Working . > ven eeae VT VITUSHOO oBSSSTSEHPAVISITFAIFEDT SIGS iD Recoveuy i> At 0-3times of melting temp. highty distorted grains wit absinterat: into Bmau size gouina. ~ ‘During Recoystallization Complete quaims wit be disintegaate into AMaLL cryin. Gwaim Geoutn follows Complete Crystablizcuion If the matedal is Let at elevated temperature. HOT WORKING: . Working. of he moteual Above tne weaystalization bemperaitunel Due to Refinement of the guain Atouctune JMechanicat Fooperties Auth as -bughmess, Percentage of alngation ond oF HeducHon anea usilt be Indeared: + fosce wequined to gek the deformation 4s Less amg tneamounty of deformaton is high- } ince ther2 is a recovery cmd reaystalizalon oteveny. Atage » tnere 4s No Stpain Hardewming. amd Nod - Gauk, Aroma. Due +0 oxide Formation wough Qunfaces cam be Pocuced. Due to ahyinkage of themaiwuad duting cooling, dimensiemat Accuracy, Wt be Less. Tooling Cost is mone. COLD WORKING :> Wosking of the mated al below the re@ystallization - srength omd Hawdness WiLL be inueared due to strain Handewing. By Gmtavlting He Roce applied grains ost. be deformed In O Angie civection and divecHonat Pooperies Com be Rood. ced. dimensional accuncey and surface Pnidh is High - Thene is a fosibility ctr Coack foamation clue to Strain Handeming.Amount of deformahon (3 Less: To get futher defoomaton Anneating may be requined Waam Working. : > Wonking of the matetial below ME VEAYStALUZAHEN Lemp Ond above the woom temp. To get the advantage ot Both HoT and COLD Weaking usavun usogueing, Gm be used- e Flow Stress. 7 d+ Materiat Elastic— Plas ¢ OME? Mean Fiow Sires oT "|yi = jae poling | \b RY re Lagaing zone Ag= Arc of Contack G= Angle of Bite TTT] hg Vo Ana Reduction Ah= Draft Bxbave = he xe Vy = A TEN hg, Vp Leadingzone frwand tip = VES-V¥ Vy Vs-Vo Vor ap Aue ot ote =RO ce=racio” Long Ae= Riafeded 5 Length © contact (fp). On» meurace Plat Jngte from, o* exit JDID bus -yyrryw Vv Ew EF EPETVITGYVV Rolling isthe Process in which X-sle area of the object Wit be decteased oy applying Compressive fowce Ushen it Witt be allowed ‘trough votating nollens- Due to PaicHon blu yol\ex ond wlP, to/p wit be automaticaly daoum into the pollens. Along. the anc of amtact am imaginary Point kmoum as Neutyal Point at ushich divecHon of the falcon chamges fe0m Foawand to Backward ama thene. is No slip Tf the material win be alow te defarm inau tne Possible dir” tien it ts Caled Plane Stes Condition Cdeawing amd extrusion) Tf the motedat is mestaicted to defowm iin amy given direction then it Ls Caled Plane atyain condition CRolting amd foaging) ra RoR bh (2) Fe 05 XAp : Ap = Rinjected Area = Lpx8 aQ=axm length a= oS dp (Hot Rolling) G= O-USzp (cold Rolling) eel Roller AoAg OB=R a 2 « pDh sezace [Cay coo oc= RAB sn cose= OC = 2 dex a 2 = _ hh oA R & [F | cos = 1- Ah = h- i© Condition of Self Entay :—> Lon-aided entoy7] Fsine + AP “UFSino Fox Self Entoy. MCS = Fsin® ALz tane > he= !2mm B= constant N£= 0-Sho NE = O9GX12= 1o-Bmm ts6= |- Ah D = 1- toh \28° AFoos® sw ts —_—>_* 4 on No- of Passes = / Cab) max Qu2 >%/WBIP-2ABE Oud SSIOBIFARE. 2£e= RB = [ao x52 = 38-1298 mm > Ques 9/0 B] P28 No-of — Ah Pasa Gh) = bh APR = _20 =6ue )KOD ng agry Que jolws] p- 286 P= dx200% BGOKA K OA F203. X 2¥ TTX 10 X00 6° Xlo00 = 1S7 KW = BD Que [3/w8) P26 e a ® ° > A — 6, » he te D ae he 5 . 5 i > + a B D v hn = DE +80 az 2 7 OONC On= 038 Q CosB, = OC = CBBC — RBC On= 0-3X4.y39° > oN ON R ° > = | 392 RO@SOn= R-BC 2 opr hn = T+1000 7 laa a [i-<0s01-932)] D BR G-ase| a ? 5 fos Me R(1-cosen) ° oad hn = hf +DC-COS &n) cosO= - HO D“FSSC CYT TT UP ewes Youu. Que 2 / Link] @ ATE- 2022 Flow Stes’ = 207+ YIN e _ Fe se (4+ AP) ote o> Avg. How Atress ho avg. sheek _ “A sthicknen = ARE & ¢ [ode : a [cact-+aty ede ° ° 3° sil u @|- T= 4 faope¢ Hee] = aor+ aly eL 3 aoae eE= Ln (®) = 2n( 45) = 4n(4) = 028% = 207 +uly (0-2676) = 266-SSMPo. do= f Rah = Fieoxt Gon) = APR Str (4-n) = CouxIee h= 3mm f | exklo ) ugues Fe fsx 266 SS (+ ws) c Fe 350- 32KN i ay sto Que > 4 /Link! cay = 30% (0° fe o26r +t k= 530M) = +224 Mm m= 0-26 254-224 mPa, = ke — Caug corel ISpione = 1 1SCavg = (asx 4-224 E= On (#3) = n( 12) 2 0S108 aanF= Spiane xAp = Oiane xX teXB = Hosa1 x JRooxy x20 = 929-78 KN T= FQ= FXOsQe = 229-18X0S X(28-28) = 3249. 206NM P= QT-CO= 2XB2N9-206 x BTK2OO 60 que- slink Elongation factor = AS = 1-22 Ag Bo fAom \ Aen) — 1S0X 150 ae | Ab } ar | 250 X 250 f gee | wh ve) mee ywYue 2|u0p|P-985° ‘2iWBIFH AG hoVo = hnUin = he Uy ho\o=hn: Un = he Ve hne hp-+0-25dh hn= he + (/-Cas On) D hn = he +0.254h = 20-+0-25(5) b Bewand slip = VE-Nn_ = (228 2S" -') Xoo = 627% Va VE ee Ve ‘ iy Backasand alip= ( Vx-Vo) _ /jVo\ - (y-2128 \xloo = Is 7% th al ) (' i) = ( Hae) VyRoll Bending > = , ZB. ZZ By Rectucing iamern of the Roliex Pouren nequined in selling operation wulbe reduced: Bur Even Smalt Roll sepanatng fooce Is Sufficient to deform the Rolle - Due to this there iba Possibility of bending of the oollens Due to Roll Bending. Non- uniform tuckness com be Peoduaced on the 00/P To overcome. ts Camber is Providec! on tne wollers Buk thy wut be wedi I marsd PaDducH or) only.2 Rolling. Stand _Axyomgment :> 2- Two high Revewivle 5 Cluster ( sendemlen) sendzmier) C) oo me + + + Fis £ : 21 ne 1 NT6. Planetax Roll ot oy ve 7 Tand@n Roll ingFatetion til] diagrarn Angie of nip eez au] Ly xeaiomns Beyond the condition of Seif entry. reduction com be Possible, By. Applying Some Compressive Bess at the inet of tne workpiece. due tO COMPRESSIVE AMESS Newtyat Plame is, anitting tpwands wight. (Exit). Thene Wi bea situation at which neukeal Plame Is Gincides usth vertical tris ond at this Condition aoliing is Not Possible: (tere 48 No Leading zone) « This Conditions Cotled Rolling Ure Angie of bite at nolling Limit js Caled Angie oF Nip - Phessune distribution under-the defamation zone is known a Faickion hill diagnam.. Aiea under tis diagnam unit indicake enexgy vequined in polling openakion ° Roling pefecks ‘7 : i i tne Wavy Edges: tint due to Roll Bending defexmnation o SEQ ATP pect A be aagpeat the edge then "ue io whining of | co cesmapane *2 ¥ CO tne Sheet oF tne edges thene fs a | possibilityo? bucHing omd clue to tia woayy edges Com be form: jotniceness rato will be Less for &. Spoend: » wiath WN Cre view) a. given eoakpiece, WEN it 1S QLoured a gnaough the voller tere IS 0 Posi bi My by widin of tre volled obj ec Will be wg increasing [retwn a» Spread MN 23 eype@wewwweewew ww enw vee ny Fooging? Foaging isa Process Ih which Makedat com take Place. Q pain of dies 4 Fuulering opercaxion > By sing convex type of die extomal Pressure Can be Appiled on tine w/p Auch that MetoL wit flow from centre tpoutside by decteasing the diameter Length of the wip wall be inc-ease Prdie > 9. Edging opezotion = By ing Concave die extumnaL Flow of ‘iojeniol wit takes Ps? oy vecucing ane Length came ° Tyfes of fouging-” Uyfes oF fox ie Hamnener 4 L-> Biller Lopenaie fouging deformation of the by applying Compressive joad using | concave die Fig: Edging Poessute Com be applied on thew/P, fiom ouside tpusands the Centre| of the WIP WH be increased VY Wi, D Vf Me Y, Ay Y 4: crsea ie gi"g 254 open die fowging> By Poviding the billet on the die Hammering force itLbe apply wD deform the object inte tne zequined Shape of te die, | Due to direct Contact ofthe hammen With wip Sur ace WiLL become Bough omd Surface Graks maybe fomned. & Sgenevouy used fSx Simple shape of the object: 2. Closed aie forging + Billet Is eovided bits tuso dies Hammering foxce ¢ am be tzanster to the billet though the uppendie: As there is No contact blu wlpand Hamme surface finish wilt be bette, And thene I's No GsackS GN the ud/P. Some opening Is Piovided at tne open aie kmoum aa Gruber Some extva Material Can beadded to the Stock Such that " duning foaging tna extra metal con be atuipwed tneough tne Gutter kKnoumey Flash - Thickness of the Flash wu be depends on Forging Load Applied clue to tne Flash Complex Cavites in the uppen aie cam be easity. Filed. 2 Impzsession die forging > Tt [Ss Just Similan to dosed die Aonging but thene 's No GjuHen and Flash - i, . . pesign of the dies in impression die forging ts Cai cal .e Analysis of ° of i Raging. : > ) - gpendie forgin: slab method of Analysis :-> 4, Rectangwian Ban Araissis Foxging:= P [> upperdie jee P \ > lowendie Qlo A au ), TREATH B a xB al ho c oak dx wevewyuevn = constant doe | Ty. . te P [Plain strain condition] ww EFuso Cox+dox) Bn—- OR BH —2Try Bda =o Oh + doh- OHKN-2TaydXx=0 AG. _ Tay 9 Fo) dx h Thesay of Plasticity: 7 eee maces) ® Yon- mise’s Theowy! * 2 2 (re ox) (R-3 + CBD 2 256 [B-4c0%- -pyy + fEace pth] ML (cha ox) = 267 eu% 3 far] = 205" A Boe -% w Ox+ P= 2k Tae 5 a 4 -7y7gyuwuevvvyurvugvue © K= Flow Shean Heese 272 Tsesca’s Theory Teesca’s Theor Or 0 =O05 oT- 4 RAP= 0% kB ~ Oxtp= 2K dom. +a eo dx dx AG = — db ©) Ax dx Faom 0 & (2) 2hy = —de h dx de = -2Tx ax P@ o Assuming Slicing Friction over the Bunface Txys UP P a Fe oP = -o4upP robe h P = -2U (ax near Pp Oh Tay: As = -UPAg SnCe= ~ 26 arc, An (ak) = -2aL +e, h t das [= x0dn(P) = 40(2k) + ae es) , ae x=L y P= Prins 2k ; d= padx Fe [PBdx 2a (L-x) Fe 28 foxe” 4X @ Assuming. Sticking. Friction oven the Sunface > ' Txy=K Li oP = -2K Ue [7 =° de h jar~ fee = PTT ps -2kx+q K = 2k+ 2b 2k = BEL +e) 3 Io ae Ol + P= 2K 2 ak + 25 (1-39) OL L=L, K=O Fnac ha ee 2kab x=0, P= Pay at X=L> P=. Prin en = PBX Free - * F= (PBdx [oS ak ok Fe2fe[ae+akc-sy| doe 2 h (3) Assuming Sticking & Sliding Both k sticking & on ; t Sliding. XXL Xx=0 Xs—> Sistetdad Sticking Length Pe Bet 2K (AEX) P= -2KX +e, h ok Ka Ys, P= he Poa ~ BE xs +1wwe uw bweervuervuevuew ee eee er vwuere we, ing + Fotding See eeeen ene 24 (L-~) Pe Fs + 3K (Xs-x) + ake 2k 2k At x=2;, 5 Pa Ps “oxy= UR=K 24. (L+Xs) R+ 2K (X%s-X) = 2Ke n 24k (1X5) K=2Ke A 248 (L-Xs) ace” 244 Xs= LB An (Ga) 4. Tf ¥e sticking Xs PL? sliding. ee 31 eon tl‘pf Rectongulan. Ban * Xg= L- bon =) . Qu (a5 Slidin: yl ae | P= axe | Sticking | P= a+ 2K (1-2) Both maw) P= Ppt a8 (hp + 2ke og Axigymmetzic h L Ro = R- Bm (5) fe Tresca’s = pee bh | Rss Ro oa | Sliding, | © fey P= Oce P= c+ 2E CR») hn Qn (aa) i—> Yon-mises | eo 2H CR-a1) P= B+ 28 (Ro-m) + ae”que? d/Lins! Feaging- — ho 2Lo 28 %28% 160 mm AA=0:08 7X 112 ¥ (60 mm . in au B QL=N2 L= 56mm h=7mm Xs=t- FP anf 24k au) ee a aout (axes (7mm —ve Conly sifting) Xs 2 Gun 2/LinK/ FOO" 91, B au% 2ux 1somm 6 x 96 * Isomm au a L248 mm hezémm . \ Yee Us— ek. ANAK s= UB (z¥as) Xe= 3g.6mm Ctve) Both Sticking & aiiding- Peak id sticring ga 6b mm? Siding.Es Th Case of foxging there IS No Need to Ca\culate Avenage Flow Stress. Because Load is applied Suddenly. (Iinpack Load). Flow Stress wit be equal ofr = 03 = ke” 1 Rerasmna~ 38 an ( Fxsei) 2xosil [Rs= 2546 mmm . Que 1g /t8] P-290 Tat y Og =o5= goormfa oH = 4omPa |< ope og = tomnh Lresmpression] B= According to to Tresca cmmaxtimnun Sheax arress CHtetion) G- B= — Yo - G3 = BOOMS, ado mf 35+ Fouging, Method 4. Dvop fouging. > a—> Ram Cr PES mah d_» upper die Gthwee J | - PE, =o —— TT | WD= APES mgh] | 2. faess Fowging > 1 Power Riess 1 F r 7 Ram O |e urreraie (he) I TELLe WD-= FxAh LS | bene comers + ingh = FX Cho“) 3- Machine forgine> | (upset fewging) . Fe oxAP | @ open die . > closed dre 2x9 pale 73d _ die, I VILIR. tinge g & AE ge ET ©) smith Reaping: > 7 r Vs plang ae —— > Anvil Seoulfoduceq. : ane of misalignment oF two dies. A: There is a fossibinity yess Roging:> The Billet js Provided bjw Upper amd Lower die emd PEE EES Pee gs8 £2 & gps wm af Res j 7 a & ® 20 : 6 Mecnine foaging oF Upset foxging > Th this keehnique defoyrnation cam 0 take Place only ak the end oF the c)p. By Fixing the wyp in theclie 6 extemal Plunger foxce Can be applied Sudcen| Q the WIP amd that end wilt oe gekting defamed to get the sequined 9 Shape. 2 Smith Roxging > wip wide healed in a fouge ox innace amd 6: 4 Fovicing on the Anvil Hammering fosce Com be applied manual, E d Pdeformm the opject Accunauy oF the object wilt clependa oy > Skill Level of the operates: Ttisq old technique. Swagin: Rotax Swagina) Sotaay Swaging) di ~Sn ZB Po Th swag ation w/p is suvrounded oy No-obaoteuting dies oa tina: oth, apply repeated Impact. blows on the ue Oy © ble + Sven that w/p ull be deformed UL direct ons unify 8 rd in Haydering MU taxes race. [+ tL wed eaten Yn demote eae vod, tubes Paodlucing of “Peed tube, Dd d ) d ) ) ) ) + ak ome of the endo? 37foorned Rolis Gepoved Rolls Ih this feocess w/p is reduced in xX-sic Undergoes changes | In X-S/c uthen it ds Passed thaough a Pain of Gravoved Rolls ' \ \ | { Forging Defects :> a: cdidSnus € ids 2. Coacks 3 Unfilled Sections 4 dle shift hm a 4 cold Shure Kfolds :> Ttisa discontinuity Boduced ushen two susfacex of metal fold against each other widaoud=fassi” = 2- Cracks > Duet Non- Uritfoom colli Ng and Shemkage ackS Cam be Soumed on the Muiface £ Inside the w/p also- TH discontinuities an€'-Prmed through the disconbinuit Cacks Utur be Poopexsted: omd the discontinuities ane known?Flakes 3 unfilled Sections :-» due improper die design Coviti i + . 23 C1 Ge one Not Compelety filled Known as unfilled Sections 4 Die shift: > Due to Impaopex Positioning BF tuo splis of dle there Is amismakch along the Paxting Line in the object: 5. Scale Pits .> 5 Scale Pits water Th case of Hot foxging oxides witt before ee onthe w/Pand the oxides wi be Stick on to the dus face Gnd once the oxides ui disappeay after Some Hime Cavities Witt be formed on the Sunface knoumas ‘Scale Pits.’ 6-Impaoper Grain Growth +7 Tf the tempoxajunte Crsadi ent Lavery +ligh duet Non unifoom Cooling. oy fouming. Non- Uniform geains Anisotaopic Réopertes ane Peoduced In the MafeLoL- F- Fins and Rags!> Ab High Lemperaturies Smalt size loose metacm be daiven on -the Surface of the Ww/p Knoumn ay Fins and Rags When the Hot Billet is 8 Baryeling : > 4 Provided blw the two : VIde 1. Bulging ty ! dies mowe deformation Ut ak the Centre When Compare to topand Ev Bottom o€ tne wy/P. this I's due to Feiction Between die and w/P, due t more heak tyansfn fsom the He To Ovencome this Luloaication is Phovided or Tsotnesmal Fesging can be used oo, em q 5 ie will be maintain Same iP. ” Tsothewmas Forging H/P ond AID @PVOVvvgv~ewegevuVyVvEeEwerwur~~- iQue- S/tink] Baaing do= Joomm ho= 50mm dea ? hg= 4omm Gea Boma Ah = 50-40= lomm WO= FXan = OBKAEXDh = BOX T xcu1-B) Xo Jooo WD = 7 BKT Engine Crankshap} > Forging. asthe “Hat he © (joo) x50 = de Xdo £= 18mm | —— 2) é to kw Hy WND= Mgiy 7:85 =10Xh h= 0185 co“4 peawing? Beu Cr conics Lan cing elie? = Semindie - Angle , — 40~20° Sy org . die Matoual > 5 Tool Steel, Die steel, Twoutar. Cazivide aria dicmond G appaoach |" Lapatcants : > Lupvicants liquid: Soap Sollutions , different types of oils- ' eno ————oeeeeees Golid :> Soap powder , AIL Gisaphite Powders - Sulfidies Cmolybdenum disulfide), Phosphates, molten glass, Delta Gilage- ES gead rnetu zones dundant Oo Fouce to Re defoornation — Friction + on PIOCLSSE ANE Hon Pickling + Alkaline coating. + Lube done he fore entering. ne He:drawing is Peocess {y Ushich Xsle ane be dectease attowin, qQ of Income matertay wouy G through a comical die ang boy. applying. tenmile fowce. on the Incoming materiat either Bend Sx-toist is Peovided t demove the oxide Layers kmoum eur Plekling then bores, COM be Peovided. after try “hey will Neateg By sHakin the Wip Kide forrnarion om the wip, ig the Cakings on Lulssicamts Cit be Sticking B= Cot a= os (42) [ (s2)"] Fa= oix ag© pitnouk FHcton:> (Idea) care) D Og= Oodn (& : Ae Fd= OgxAg Maximum Possible Reduction > Oo” oa= op oa= oan (35) eae) ; es el= 2-718 7 Reaction" = fone I G x - (5m) = 63-247 > Ques Isto] PR 83 og = goomfa OF = do= fomm : des o gxlo= 8mm = oean(32)° \ Fas COXAL q P =[% ao ( Soh xe |x? a pe oq > Of > breaking, 43n=0 4 Ques (S/o BIP-2S4 how AF =0-35 - Ae v 2R0gea Ro Ag x AL y--- x Ao Aas Ase Pot Ao: Bor = At, Leg A = Az = ois) Bor At, 0°65,4 ee oe in( oh = anf = (sw) = 305 Ah (1S i. > Gs) - = 1 \t L&,= \oox (se Span Gut tleoe)p-204 Ro, Aor Og = 55 In ( me) Fas Six Ag ' Tt introee Fa= [02 (sz) | (10) Koes Wes 96/08] p-2.94 LO) = bo (+t?) : = Qh A] e= an (ire) lepton ae eee (arte ide)~»> Que > 29/8] P-A@I5 (25mm dia —> lomm cia rr loom/min A=5° ws0ls 5 Og = 400 mPo 28 maa 6 rey (28) | B do B= yat< = 01S X COESP = I-7IY . OX\TIN Shs 400 Aah q- Gz aM 125 = % Gro,Faz Og. Ag 6X aL A= [s eco | P= Fav = [aepsxtoas Jag P= 44-32 KW 7 Reduction in Fieg = Bo— Admin 0 @) sox: fossible Reauchion e Oz = OB ' d atin ; ¢b-71U (se fmin } 400= ‘| a - lao J . ) Ibn = 934mm ’ ‘ r ' ' [z- (aay ] x00 = uyFé 12s) 7 Reduction in diameten = do- dé min to -(&- 220)eto0 = 25-097 las, (a) With Baus Tension an 28) 2 a (9) [-) +0 (22) 2X} Ty ods +6 + SO _ Sco 's = 61 asm mor Possible Reduction 1, awn xb de ini) (tain J") ay (tae) goo doo HEE If a) | Rs J | Seine 9st -F Reduction inchia= 4 démin af- Lt) — 23. ee ras | 46x do J | X1o00 | - - | Qot + 4/ Link) Drawing K= 500 mq N=0-3 | o3 | SS = OByg = KEN _ S00x (0-575) at) ost = S25.8umea er do\ 22) 2555 eras (ac) = (45) Oo S35 2B og = oxy ($2)/: ~(#) i xQ-3786 “peav (amet) [«- (8) y 4 2:3186 WV Sg= gus-osmPa. Fa= Sax At P= Bo Aa xust xe P= @ss os4 P= 121-95 KW ieee2 With Floating mamdwat drawing is Penfowmed witnoux Paovidi e. we ate Not gett ng ber Tube sinki zntuve sinkin sinking? = Me ro 1 Oh the ouxgoing. que org : a Ae ge - Incase of Footing momaval since thene fsa euppost Inside oftne tue > guaface Finish wil impaove four tnene Cortao\ ONE gne dimensions of outgoing “tube. Wilmot beoMy tn cose of Fixed monde | S oy D3 e ing ee Fosce on the mom dre higner istne fxce on eae. mom aT Lesser Wirloe tne thiccness of outgoing tube and Buxfoce. Finis ok the tube Wi A440 Um £30). andsel:in case of moving momdeat , mandyat (sin tn > ao a with moving 4 ik Wit © A i Pam of wane and It 2 Ceninuswely moving atong with the efi of ene ouxgeing tube. of the twoe “moximnura FEGUCH ON in the ¥-Slencom be Possible in this technique inside Suwrace Snysuppast tne! ndalso We dont have amy comtao| over mensions} unjoeness of ousgoing tule Carn be Conteol iarneren o& the momdy ot WU be equal to inside diameter eae i° Bundle Drawing: > Defects in Grauwing operations» SESS th deranoin 4- Cenbse Line Crack :> due to Impoopex, cleaming %, OF oxide hayous onthe rm, In coming workplece clung § Sere — aeawing” oxide Layers ( ee Gen be Penitwated’ towards ( WL fom cadas in the O/Pat the centie. ! P " o Qo These ane the Longitudonat Sakehey Proctuces on tne w/P h when it Win be ALLo ured trough a wMDugh Buntace of the 4 die i 8: Crotks:> Ty Cold Wworkina, duo, 7exes > f _1— yor CoD gx word Backwand ; (civect) (Indirect) Hydwostatic Tmpack : (Foowand) (Back wand) Foowand (Divect) Extousion: > containe. ie vie Extousin = Ae a Zy a pron | AP EA é La oe : Pinger lee acme Backward (indirect) Exta sion + -» container \ die i gillee | ' rH \ Ram ) CHollow) Plunger. \ (Hollow) \ by, \ 4 load \ \ > 4 Poo, da displacement displacement a rect) Extauslon Barkwond (Indirect) Extusion 51Posten Extausion In Foot and Extous moment of the Plunger usitybe in the Same direction of gxtouted Rat» Tt Is Eosy to Honctle the exiswed Past Life of the Plunger ema tHE Ram wil be move. Due to moment oF the Billet inside the Contaimer . Contain » fyicHon GNU be more Pressiuje Tequurer AD overcome the FaicHon wi be move Backward Extrusion To Rackwand Extousion extsuted Paso wittt be moving in tne Opposite dimection of Plunger moment thene isNo moment of. the Billet inside © the Container. Containen ficHon wit be Negtigibie. ae Presse ALWINS fy extrusion WUL be Lege. Tt Is dif cutt to Collect Exeuted Pas: Pern the Moving Plunger. Life of the. Plunges. and sam OU be Less. fer the Same amount of Reduction as -33/ oF ehengy win be Less tn Tndivect Exipusion oshnen Compane to clirect eytaucion. + Hydrostatic Extrusion: (Feswand) sgoomta Lydie 2. 77 crm —~ Ta Hyd wautic VZZTTLA Fluid Plunger ~ Billet: Tra cntainers by Boviding tne billet hyclsaunic Puts can be Sived Such that ene is No contact bl cmtainer nd Billet through the Plunger Psressune jin ceased Inside the Quid. The hydnauic fuid wit Apply uriiform Pressure, 9 the Billek due to tnis defowmation com oe take Place in the Wh Billet it can be wed fox Brittle and Hond mateniers Piso: for Battle maka cuctitity wu le Slighlly increased mown as Presse induced ductility. ‘DOU Aire crisApplications +> Used fox Cast ‘Thon, Stainless glee), molebdium ete. ¢ Impack Extousin:> . ——___ Cindireck Extausion) ~ Punch AVY Soft osm of the material 23 Rovided inthe cliea Heavy Punch is Allowed through thecie due to Impact force applied by the Punch Soft fosmof the metal enter into the gap beldeen Punch and die and the soft metal t's moving In the opposite direction of Punch moment it I's genenaLiy used x Soft material Al, Lead, Tin Zinc ete: Application: + Collasanle tube, medication tubes , toothpaste tuber CAlaminium} tubes Ured for creams ekc. * Load Extousion without Fiction 1> ‘ Re Extausion Ratio = oe Tohnsor's Equation. 1 Ge = Oe far ance) |fP>ord G,b ane Johnor's Constant Oe = K' BnCR)T? HOT > k'= Extousion Constant 7 (depends on tempenatune) WIN feictim :> oS) Sa sal* Foowand Extxusion: > Ko Flow Shear Pee. €kL ; Shengty Do | = Ce ‘Soap | Von-misea's tq eng k= > Tresca’s theory, QR > Pressure equtned to OVERCOME the cine Fiction om Ques ie Bl2g2. Extausion ato =R 7 Reduction = ( re Ae Area ~ Aerhe) ®) A * = fa- = = (In) X10 = 957. = Que. 10/8 }293, kK Fez @ 0EXAo 2 Fe = aso x tn (188) xD coor > Que» 2)/ Link] Extoution sh WD ‘| peers > Defers a. guiface Glacks:+ Due to movefeiction omd xtausion Speed TTA Surface tempytanis be increase. and this 7/} Conditions Nay Cause SOnface Cracks & VLA. + Centre burst G8) chevaon cracking @) Axzow Head fracune> WZZZZZZZTD) =D >>? A Lange material motion at the ours Surface Pulls toe Matouiat along the Centre Line of the w/p due to this Stresses wutu be developed at the Cente beyond a critical Limit by lurking Cracks wilt be formed. 3. pipe defect > “@ Tau Pipe @ Fish Ta: > oxide ~ LZZZEEZ duxing extrusion oxide Layars £Impusdties will be deciven towands the contre of the Billet ond they. wil foum a Pipe shape Cavity knoumas pipe defeck ov Fish tail defect 4- Bamboo defecis:? Landing. guifiace. Gracies Con be Formed ak Lower temp-aiso it 4s due-to Pexiddic Sticking of Extouted Pact along theclie Lamdé tuwung extrusion, it wit ingeare the Presguie & suddenly reduced. The Gale Is repeated Ontnuudy, Producing Pesoi dic drcumtnrential Gacks on the Suitace. Te ig appearing to the} 57|F Sheek Metal woking +> CSheet < Smm) Sheaxing e 2. Penetwolion "| Rell oer depth Blank is j holdex. sek sheet « GE — ‘t Fy ~ (CA Burnishing. pee ness QP cop re oo! ol Feractute angie Scop Bust TF-the Blanking Piewdute is Very High Sheet wit be Not otto Slip, Between Blank Holderomd die go Punch wit Shean a fostion of Sheet material: 4 the Punch Penitwates the Aleck mareniat diuting the Re\l ON duck deformations ane oly elastic. pastic defownation takes place cuming the buunishing depth - AL tne endoP the burmishing depth Sheet matutal frackune atan amgie omd it wit be separated fiom tne Sheet Material. pueto Fractune angie more moterial win be cut fem the sheet ondit Ulu be aitoch to the Scvap known a f buy . DUetD tig LU Bize OF the Acrop WWiu be Slightly inveasred tne Practune angle iamore 6 Ruy? Sze win be increased. Dudile Marerials ane having more fracture onghe when compane 4p Bitte Mateos+ Punching: Punch Exact ° Blanking Blank Exact dlesize Frack tz L edie Celeanamce win be on Punch iy Blank Cup) c= Radiat cleanamce C= G-0032t [Ts Ts Shean Birength ot sheer Metay Scxap cutting fouce =_PttTs P= Peximeteor FS ema b P=2(a+b) LPH AONE = (Fema: PE) Ly Penetiation deptForce . Tdeay Powen = Femax n-Pe Feenaye 60 N= No of attokes /min —_~ Actual fower = (W-D) XN 6 ind Punch -taovel 1x 60 Pp Shem le Feext —] Las e777 . / a> Pe we SD at conkoone = Fe Cpt+S) Fema PE= Fe (PE*S) a (pets) > PE Ram = eB ion Punch Is exack amd cleanamce is Tn case of pancning a is povieed on tne Punch - ee Reovided oP core pare akon BE is exack clearance is ° of Biome vided on the aie ee pth oma shew is Peovl 61e 1 A [oi p> s-Pe PE s-pe bE = B 2a WD= LxPE xr: +6-Pt)f + SXPEK Es —— WD= RS GQ) S>Pt ©) Force Vs displacement (Txepezoiday) @) Cutting (s with Blades w= FS Fone * PE= BXS = Ques (3) /welP-295 Que» (3) /welp-295° d= 20mm += 2mm Blanking soap orm Bee Punch Size = 4-20 = 20-2 yaya i = 18-88mmQues § [wel P-295 Fmax= PtTs 2h +b)ETs - = 2[Joo+ 50] xSK300 = 45 MEX, E si > Ques! WB) P2935 R2k Oe XAc 2s Tt Cex dS te de exes te d= Abts & d= YXISK3 Ce é eS Que> B/wsl Pass S=2mm pe = ouXsel2mm TSEPE] Figen PE BS Fo Finny PE = Orde) PE) Ss Ss a 5 a _ ne ee imm IND = Fomax XS = (PtTs) x0 Pt = (Q00XS Kl00) Ko2XS” tt Rina looo LL. 7” 4 >Ques 0] WB] P-29% * 100 = Fs x10. jooo - Que >\2/a8l f-28 * Die pilowonce Punch Size d-2¢ = d-@c+A) A= dle Allowance = 25-(2x0-06+0.05) = 24-83mm 2 Ques 22/28lt 300 ole d= loomm += S-6mm Ultimose hear] Bress= SSON| me Pe te Capocty = 80 Press,fssumi ng. S>pt Femax Pt = FS S= max’ Pt Fs S=GTxID0 5:6) KEEP Ku USE Fs = 0 x1000%9.31 294-3 X10% Fs= 290-3kN |S=1-36 men Assumi ng dowble shear is oe kp tane =.7:36 Mo [rs re Ag =20* 4 As= “xB =(B+B 8) x(B+0+2) = S2x12 = est - 65# Deep Deauing > Cc Parc P P 7 5 | d Blank ; Blank = <> oidexs ; Csneek) %= Vp = Ranch covngy Fadiuy (5 f> die Wd= Radiusof die we) ja—D —t (2ZZZEZZZZA. a . Noes Tdetstdh & + 4 q t ee ickening ? % 2 [aa ean ed — + Blank size @ tf d p20 p= |d+4dh Ae ve Jaddh ~OSNe elo-lS , d= |\gddh - Ne (iy if P= ts20 Ae ay FS ne “Drawing foxce’* ~ Fas wat «3 (3-°) C= Fiction facor + with Flange +> Ckwlds 7LDR= Dmox “ POR poai-8 LPR = 2:3 To Peoduce Cup Snape of the abjeds From the Sheet metay ‘tus tecamique Combe use- Atthe bottom of the dzaum Cut ‘Nickmess fa Bimilas -to CviginaL Sheet becauxe thene Qneé No sbesser cppeating ak that negim- In the Punch commen negion there Wil be Necls fommation Cthickness wilt decrease) becaune max. Punch Load I's appearing in ta region In the Cup wat due to Compressive Hoop Stresses tricknett USUAL oe increaaing 420M Bottom totop. Inthe Flamge compressive Hoop Bhesse: asl be develope: | TR overcome truis oy Paoviding . Bom Holding Pressune Radial tensile stresses, ULL be devetopeg. Litsiting. doawing RaHo (LOR)> vik Te js tne mox diameter ot Blanis ae be daaum into the cap to diamekr ob ne cup. “th i tne Poopest tne moteriot: for A\ 21-8, For-ateel oe ee =2-2To Reduce cleepen Caps more noo This Cam be Possible b ? dyaws will be eequined Incase of ty Peovicking Redsawing openation. fix eg; Beverage cans thiee draun wit be wequined . ‘Deoning operation -» lt IsQ Peocess of maki ng. the Uniform thickness of the Wal ina dzam Cup weinkling :> Dueto Insufficient Blank Holding Pressure Wirinkles Cam be Fowmed in the flomge cvnd they may extend upto Cup wall. Dueto excessive Blank Holding Pressure By fowming the Neck fradune Wit takes Place ak the Bottom of the cup. ®& 2- ovonge Peel effect :~ TP the wip is having Coaure graim Stauctune dueto may: deformation ak tne Pun ch Coser Nadias nigh ZunPace Cam be aT Thaeane Strechens over the dsaum Component Caused by Plasticdefosrnation dueto Tin Homogeneous yielding Cyield Point Phenomeona’) 2 boesnox. sigaind i? 694 Deouwmanks: > ashen the wip wit bedseuLm on the gough Burface of NE dhie drawmarka Wit be fommed: S- Eaxing > While deauwing a Rolled Sheet , Ears oY Lobex Can be fowned due to Anisotaopy incuced in the maseniaL & Mis Stake Due to Impeopen Positi ening of the Blank over thedie unsymmeteical Snape of ce : the cup Con be Produced. | > Quz. 2 14] wB)297- d _ 100 =250 He oO" g >20 p= [d+ 4dh = | Gooy+4lloatieo) = 22uMnm D7 5/98 /299- Ase 18 De [Praan = | CG (is = 150mA capot m aia Zioommhzight isto be dzawn Fecmlou Cavtoon Steel Sheet. cqlalare dia of Blank and determine No of clectuctions Tequined by consicering 407. reduction. in each eexe dawn. gf — g=5omm 7 = = in h= loom 2 |. oe D=2 D= loo = \Somm qo/. REdUCHON Deda O40 dy= 0-60D e060 7 D dy=o6? y= 0" 6AISO = gomm Isa destin nm