Hot-Working: Rolling

N
Flatness Control
 If a roll is always used to reduce the same
material at the same temperature by the same
amount, forces and deflections can be predicted
 barrel-shape

Forming Processes 35
Hot-Working: Rolling
Flatness Control
 Barrel-shape

Forming Processes 36
 Hot Working – Forging
กระบวนการ นรู ป โดย ยก

Forming Processes 37
ขึ
ึ้
Hot-Working: Forging
Forging
 Induced by compressive forces
 The oldest known metalworking process

Forming Processes 38
Hot-Working: Forging
Open-Die Drop-Hammer Forging
 Impact is delivered by mechanical hammer
 Open-die forging does not fully control the
flow of metal, the operator must obtain the
desired shape

Forming Processes 39
Hot-Working: Forging

Forming Processes 40
Hot-Working: Forging
Open-Die Drop-Hammer Forging

Forming Processes 41
 Hot-Working: Forging
Impression-Die Drop-
Hammer Forging
 Using shaped dies to
control the flow of metal
 Excess metal is squeezed
out, flash, and trimmed off

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น

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- อเ ย เศษเเห อ อน าง
:

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น านไ ผล บ อนก ก Open

Forming Processes 42
ต่
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Hot-Working: Forging
Impression-Die Drop-Hammer Forging
 Fine recrystallized grain structure (hot working)
and absence in voids (compressive forming
stresses) made higher strength/weight ratios
compared with cast or machined parts

Forming Processes 43
Hot-Working: Forging
Press Forging
 The slow squeeze action, producing
a more uniform deformation and
flow
 Heated dies are used to reduce heat
loss, promote surface flow, and
enable the production of finer
details and closer tolerances
 Higher dimensional accuracy than
open-die forging

Forming Processes 44
Hot-Working: Forging

Press Forging: Mechanical presses

 Cams, cranks or toggles to produce stroke
 Different forces with various stroke positions
 Fast production rate

Forming Processes 45
Hot-Working: Forging
Press Forging: Hydraulic
presses
 Moving response to fluid
pressure in a piston
 Slower, more massive, and
more costly
 Much more flexible and
greater capacity

Forming Processes 46
Hot-Working: Forging
Upset Forging
 Increasing the diameter of metal by
compressing its length
 Forging motion is horizontal and the workpiece
is rapidly moved from station to station

Forming Processes 47
Hot-Working: Forging
Upset Forging
 Starting stock is usually
wire or rod
 Usually form head of
bolt and other
fasteners and may
other small
components
 No required trimming

Forming Processes 48
Hot-Working: Forging
Roll Forging
 Round or flat bar stock
is reduced in thickness
and increased in length
 No flash in most cases

Forming Processes 49
Hot Working – Extrusion

Forming Processes 50
Hot-Working: Extrusion
Extrusion
 Metal is compressed
and forces to flow
through a suitably
shape die to form
product with reduced
but constant cross
section
 No draft is required

Forming Processes 51
Hot-Working: Extrusion
Extrusion
 Many shape can be produce
 Massive deformation, large amount of heat are
generated
 Lubricant is to reduce friction and barrier to heat
transfer

Forming Processes 52
 Hot-Working: Extrusion
Direct Extrusion จเ น ประเภ แม 2

 Ram push billet through a stationary die

ให ดอกัน
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้น D imiter R

นง
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ตรวอ

Forming Processes 53
ชิ้
มิ
ชั้
ที่
มี
 Hot-Working: Extrusion
Indirect Extrusion
 Hollow ram push the die back through a
stationary, confined billet
 Required lower force and longer billets can
be used
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Forming Processes 54
กั
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 Hot-Working: Extrusion
Hollow Shape Extrusion
 For tubular products, mandrel processes
are quite common
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Forming Processes 55
้ำ
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Hot Working
– Drawing, Pipe welding, and
Piercing

Forming Processes 56
Hot-Working: Drawing

Hot Drawing
 Flat sheet or plate is formed into 3-dimension part
with depth more than several times the thickness
of the metal
 Remaining flange is trimmed to the desired shape

Forming Processes 57
Hot-Working: Pipe Welding
Pipe Welding

Forming Processes 58
Hot-Working: Piercing
Piercing
 Thick-walled seamless tubing can be made
by rotary piercing

Forming Processes 59
Hot Working
Pros Cons
 Variety of shape  Lower accuracy

 Lower forces  Higher total energy

 Oxidation
 Fracture parts in cold
working can be  Poorer surface finish

formed  Shorter tool life

 Isotropic properties

 No strengthening

Forming Processes 60
Cold-Working Processes

Forming Processes 61
Introduction

Cold Working
 Strain hardening acts to increase the strength
 Weaker starting material may be selected
 Surface finish and dimensional precision are
quite good
 While greater forces are required, no need to
heat the workpiece

Forming Processes 62
Cold-Working Processes

1. Squeezing
2. Bending
3. Shearing
4. Drawing & Sheet Metal Forming

Forming Processes 63
Cold Working: Squeezing Processes

Swaging
 External hammering reduce the diameter of
workpiece

Forming Processes 64
Cold Working: Squeezing Processes

Cold Forging
 Manufacture of small parts from the weaker
nonferrous materials

Forming Processes 65
Cold Working: Squeezing Processes

Extrusion

Forming Processes 66
Cold Working: Squeezing Processes
Extrusion

Forming Processes 67
Cold Working: Squeezing Processes
Roll Extrusion
 Thin-walled cylinders can be produced from
thicker-wall material

Forming Processes 68
Cold Working: Squeezing Processes

Riveting
 An expanded head is formed on the shank end to
permanently join sheets material

Forming Processes 69
Cold Working: Squeezing Processes
Staking
 Permanently joining parts together when segment
of one part protrudes through a hole in the other

Forming Processes 70
Cold Working: Squeezing Processes
Coining
 All of the surfaces are confined within a set of dies

Forming Processes 71
Cold Working: Squeezing Processes

Hubbing
 The hub is pressed into an annealed block until
the desired impression is produced

Forming Processes 72
Cold-Working - Bending

Forming Processes 73
Cold Working: Bending

Bending
 The plastic deformation of metals about a linear
axis with little or no change in the surface area
 If multiple bends are made with a single die,
called forming
 If the axes of deformation are not linear, called
drawing or stretching

Forming Processes 74
Cold Working: Bending
Bending
 Neutral axis
 1/3 or ½ of the way from
inner surface
 Springback

Forming Processes 75
Cold Working: Bending
Angle Bending
 Bar folder:
 can use to make angle
bends up to 150° in
sheet metal under
1.5mm thick
 Linear bend

Forming Processes 76
Cold Working: Bending
Angle Bending
 Press Brake:
 more complex bends
 Different dies can be used to produce many types of
bends

Forming Processes 77
Cold Working: Bending

Roll Bending
 Continuous form of three-point bending
 The two lower rolls are driven
 The upper roll is control the curvature

Forming Processes 78
Cold Working: Bending

Draw Bending
 The form block rotate

Forming Processes 79
Cold Working: Bending

Compression Bending
 Moving tool compress the workpiece

Forming Processes 80
Cold Working: Bending

Press Bending
 Press ram moves the bending form

Forming Processes 81
Cold Working: Bending

Tube Bending
 As diameter increase, wall thickness decrease or
bend radius become smaller

Forming Processes 82
Cold Working: Bending

Straightening
 Series of reverse bends into flat or straight
profiles

Forming Processes 83
Cold-Working - Shearing

Forming Processes 84
Cold Working: Shearing

Shearing
 The mechanical cutting of materials without the
formation of chips or the use of burning or
melting
 When two cutting blades are straight, called
shearing

Forming Processes 85
Cold Working: Shearing

Shearing
 When the blades are curved, called blanking,
notching or trimming

Blank Piecing

&

Forming Processes 86
Cold Working: Shearing
Simple Shearing
 Punch pushes the workpiece, material flowing into the die
 Clearance usually 5-10% of material thickness
 Metal will tears or ruptures

Forming Processes 87
Cold Working: Shearing
Simple Shearing
 Using shaped pressure plate for smooth edges

Forming Processes 88
Cold Working: Shearing

Slitting
 Cut rolled sheet metal into several rolls of
narrower width

Forming Processes 89
Cold Working: Shearing
Blanking
 Metal workpiece is removed from the primary
metal strip or sheet when it is punched
 The material that is removed is the new metal
workpiece or blank

Forming Processes 90
Cold Working: Shearing
Notching
 Metal scrap piece is removed from the outside
edge of a metal workpiece
 Typically a manually operated, low-production
process.

Forming Processes 91
Cold Working: Shearing
Progressive Die
 Two or more sets of punches and dies mounted in
tandem
 As process continuous, a finish part is completed
with each stroke of press

Forming Processes 92
Cold Working: Shearing
Progressive Die

Forming Processes 93