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Forming
Forming
Plastic region
A
Elastic region
Hot & Cold Working
Hot working
• The mechanical working of metal above
the recrystallization temperature
Dis Advantages
• Surface finish is poor
• Close tolerance and automation is not
possible
• Tooling and handling cost is high
• Porosity will be eliminated and density will
increase
• Sheets and wires can not be produced
Hot & Cold Working
Hot working
• The mechanical working of metal above the recrystallization
temperature
Advantages
• Force requirement is less
• Grain stricture is refined(improve toughness and ductility)
• Quick and economical process
• Porosity will be eliminated and density will increase
• Fracture can be reduced
• Metal forming performed at room temp or
slightly above
Advantage Disadvantage
Advantage
•Lower forces are
required
•More intricate work
geometries possible
•The need for annealing
may be reduced
Isothermal
• For high speed steel, titanium alloy, good hot hardness
Cracking
Metal forming process
• 1. Bulk deformation processes
• 2. Sheet metal working processes
force
die
Ao blank Ad
force
Bulk Deforming Processes
• Forging • Rolling
(wrenches, crankshafts) (I-beams, rails)
force
die
Ao blank Ad often at
elev. T
force
• Drawing • Extrusion
(rods, wire, tubing) (rods, tubing)
die Ad
Ao tensile
force
die
Extrusion
Metal forced/squeezed
out through a hole (die)
[source:www.magnode.com]
Typical use: ductile metals (Cu, Steel, Al, Mg), Plastics, Rubbers
Common products:
F (pulling force)
• Shearing
Forging
[Heated] metal is beaten with a heavy hammer to give it the required shape
Hot forging,
open-die
Forging
(a) (b)
[source:www.scotforge.com]
Grain Flow Pattern of Pierced Round Billet
Figure 14.12 A pierced
round billet, showing grain
flow pattern. Source:
Courtesy of Ladish Co., Inc.
Grain Flow Comparison
Figure (a) Solid cylindrical billet upset between two flat dies. (b) Uniform
deformation of the billet without friction. (c) Deformation with friction.
Note barreling of the billet caused by friction forces at the billet-die
interfaces.
Impression-Die
Forging
Figure 14.6 Stages in impression-die forging of a solid round billet. Note the formation of flash,
which is excess metal that is subsequently trimmed off (see Fig. 14.8).
Forging a Connecting Rod
Figure 14.9
Comparison of closed-
die forging to
precision or flashless
forging of a
cylindrical billet.
Source: H. Takemasu,
V. Vazquez, B.
Painter, and T. Altan.
Unit Cost in Forging
Steel Plants,
Raw stock production (sheets, tubes, Rods, etc.)
Screw manufacture
Rolling Basics
tf Vf Vf
to to tf
Vo
Vo
stationary die
Screw manufacture:
rolling die
thread rolling machine
Roll
speed,vt R=roll radius
p=roll
t0 pressure tt
vt
v0 L=contact
length
vt
Distorted roll
Original shape Distorted roll
tmin tmax
Cross section of the sheet
Rolling force
Various Configurations
vt vt
v0 v0
v0 vt vt
vt
vt vt v1 vt
v2
Two high
vt
Three high Four high
vt
v0 vt v0 v1 v2 v3
Compressive Force
Rolls
Mandrel
Tensile
Stresses Finished
Tube
Starting Cylinder
Friction and lubrication
• Friction is undesirable;
– Metal flow in the work is retarded
– The forces to perform are increased
– Rapid wear of tooling
Lubrication
• Mineral oils
• Graphite
• Glass
• Graphite in water or mineral oil is a
common for hot forging
Raw material: sheets of metal, rectangular, large
Processes:
Shearing
Punching
Bending
Deep drawing
Bending
Main use: to cut large sheet into smaller sizes for making parts.
Punching
Cutting tool is a round/rectangular punch,
that goes through a hole, or die of same shape
t sheet
die die
clearance
Punching
nesting of parts
Blank (Part)
Slug (Scrap)
F t X edge-length of punch X shear strength
et
die die
clearance
Punch
Die
t sheet
die die
clearance
C = clearance, C = at
a = allowance
t = Thickness (plate)
How to handle springback:
Bending: springback
3
Ri RY RY
4 i 3 i 1
Rf ET ET
part
die die die die die