MODULE 3

COURSE OUTCOMES

Rolling
Forging Extrusion

Wire and bar drawing

Metal Forming Processes

Rolling Forging Bending Cup Drawing

Extrusion

Wire Drawing

Shearing

Bulk Deformation Processes

Sheet Metal Processes

Plastic Deformation Processes

Operations that induce shape changes on the work piece by plastic deformation under forces applied by various tools and dies.

Bulk Deformation Processes

These processes involve large amount of plastic deformation. The cross-section of workpiece changes without volume change. The ratio cross-section area/volume is small. Performed as cold, warm, and hot working operations

Cold working performed at room temp.

Advantages: better accuracy, better surface finish, high strength and hardness of the part, no heating is required. Disadvantages: higher forces and power, limitations to the amount of forming, additional annealing for some material is required, and some material are not capable of cold working.

Warm working performed temp. above the room temp. but

bellow the recrystallization one. Advantages: lower forces and power, more complex part shapes, no annealing is required. Disadvantages: some investment in furnaces is needed.

Hot working involves deformation of preheated

material at temp. above the re crystallization temp. Advantages: big amount of forming is possible, lower forces and power are required, forming of materials with low ductility, no work hardening and therefore, no additional annealing is required.

Disadvantages: lower accuracy and surface finish, higher production cost, and shorter tool life.

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

The rolling process (specifically, flat rolling)

The Rolls
The rotating rolls perform two main functions: Pull the work into the gap between them by friction between work-part and rolls Simultaneously squeeze the work to reduce cross section

Types of Rolling
Based on work piece geometry :
Flat rolling - used to reduce thickness of a rectangular cross section Shape rolling - square cross section is formed into a shape such as an I-beam

Based on work temperature :

Hot Rolling most common due to the large amount of deformation required Cold rolling produces finished sheet and plate stock

Some of the steel products made in a rolling mill

Flat rolling and its analysis

R = roller radius p = roll pressure L = contact length = contact angle vr = roll speed to = initial plate thickness tf = final plate thickness vo = plate entry speed vf = plate exit speed

Side view of flat rolling, indicating before and after thicknesses, work velocities, angle of contact with rolls, and other features.

Flat rolling and its analysis

The work enters the gap between the rolls at a velocity vo and exits at a velocity vf. Because the volume flow rate is constant and the thickness is decreasing, vf should be larger than vo. The roll surface velocity vr is larger than vo and smaller than vf. This means that slipping occurs between the work and the rolls. Only at one point along the contact length, there is no slipping (relative motion) between the work and the roll. This point is called the Neutral Point or the No Slip Point.

Flat rolling and its analysis

In flat rolling, the work is squeezed between two rolls so that its thickness is reduced by an amount called the draft:
d to t f

where d: draft to: starting thickness tf : final thickness

Flat rolling and its analysis

Rolling may not be possible (the sheet will not be pulled) if the draft is large. The maximum draft for successful rolling per pass is: 2 m ax Where: dmax : maximum draft successful rolling per pass : coefficient of friction R : roll radius

Number of passes

to t f

R
2

Example:- A series of cold rolling operations is to be used to reduce the thickness of a plate from 50 mm down to 25 mm in a reversing two high mill. Roll diameter =700 mm and coefficient of friction between rolls and work = 0.15. The specification is that the draft is to be equal on each pass. Determine (a) minimum number of passes required, and
(b) draft for each pass.

Solution
number of passes to t f

2R

50 - 25 3.17 4 passes 2 0.15 350

50 - 25 6.25 mm
4

Draft per pass

to t f number of passes

The Flat-rolling Process: Roll Force, Torque, and Power Requirements

Rolls apply pressure on the flat strip to reduce its thickness, resulting in a roll force, F Roll force in flat rolling can be estimated from

F LwYavg

L = roll-strip contact length w = width of the strip Yavg = average true stress of the strip

2FLN Total power (for two rolls) is Power (in kW) 60,000
Roll strip contact length (L ) =

R ( h 0 hf )

w= Width of the strip

Y avg= Average true stress N= Speed of the roll in RPM

Flat rolling and its analysis

From the previous equations we can conclude the following: 1. The contact length decreases by decreasing the roll radius. 2. The roll force depends on the contact length, and therefore, reducing the roll radius will reduce the roll force. 3. The torque and power depend on the roll force and contact length, and therefore, reducing the roll radius will reduce both the torque and power. 4. The power also depends on the rotational speed of the rolls, and therefore, reducing the rolls RPM will reduce the power.

Various configurations of rolling mills

(a) 2-high rolling mill

(b) 3-high rolling mill

Various configurations of rolling mills

(c) four high rolling mill

(d) cluster mill

Various configurations of rolling mills

(e) tandem rolling mill

Shape-Rolling Operations
Various shapes can be produced by shape rolling Bars Channels I-beams Railroad rails Roll-pass design requires considerable experience in order to avoid external and internal defects

Stages in Shape Rolling of an H-section part. Various other structural sections such as channels and I-beams, are rolled by this kind of process.

Thread Rolling
Bulk deformation process used to form threads on cylindrical parts by rolling them between two dies Most important commercial process for mass producing bolts and screws

Performed by cold working in thread rolling machines

Advantages over thread cutting (machining): Higher production rates Better material utilization Stronger threads due to work hardening Better fatigue resistance due to compressive stresses introduced by rolling

Thread Rolling

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

Ring Rolling
Deformation process in which a thick-walled ring of smaller diameter is rolled into a thin walled ring of larger diameter

As thick-walled ring is compressed, deformed metal elongates, causing diameter of ring to be enlarged
Hot working process for large rings and cold working process for smaller rings

Applications: ball and roller bearing races, steel tires for railroad
wheels, and rings for pipes, pressure vessels, and rotating machinery

Advantages: material savings, ideal grain orientation,

strengthening through cold working

Ring Rolling

Ring rolling used to reduce the wall thickness and increase the diameter of a ring: (1) start, and (2) completion of process

Forging
Deformation process in which work is compressed between two dies
Oldest of the metal forming operations, dating from about 5000 B C Components: engine crankshafts, connecting rods, gears, aircraft structural components, jet engine turbine parts In addition, basic metals industries use forging to establish basic form of large components that are subsequently machined to final shape and size

Classification of Forging Operations

Cold vs. hot forging:
Hot or warm forging most common, due to the significant deformation and the need to reduce strength and increase ductility of work metal Cold forging - advantage is increased strength that results from strain hardening

Impact vs. press forging:

Forge hammer - applies an impact load Forge press - applies gradual pressure

Types of Forging Dies

1. Open die forging - work is compressed between two flat dies, allowing metal to flow laterally without constraint 2. Impression die forging - die surfaces contain a cavity or impression that is imparted to work part, thus constraining metal flow - flash is created 3. Flash less forging - work part is completely constrained in die and no excess flash is produced

1. Open Die Forging

Compression of work part with cylindrical cross-section between two flat dies Similar to compression test Deformation operation reduces height and increases diameter of work Common names include upsetting or upset forging

LIMITATIONS OF OPEN DIE FORGING

Limited to simple shapes Difficult to hold close tolerances Needs to be machined to final shape Low production rate Poor utilization of materials

Highly skilled operation

2. Impression Die Forging

Compression of work part by dies with inverse of desired part shape This form of forging is used to make more complicated parts from Blank bar stock. The Blanks are compressed between two or more dies to shape the part. Once the part is shaped, the flash is removed by either grinding it, trimming, or machining.

Stages in Impression-die (Closed-Die) Forging

Impression Die Forging Advantages and Limitations

Advantages compared to machining from solid stock:
Higher production rates Conservation of metal (less waste) Greater strength Favorable grain orientation in the metal

Limitations:
Not capable of close tolerances Machining often required to achieve accuracies and features needed, such as holes, threads, and mating surfaces that fit with other components

3. Flash less Forging

Compression of work in punch and die tooling whose cavity does allow for flash Starting work part volume must equal die cavity volume within very close tolerance Process control more demanding than impression die forging Best suited to part geometries that are simple and symmetrical Often classified as a precision forging process
Flash less forging: just before initial contact with work piece, partial compression, and final punch and die closure

(1)

(2)
(3)

Forging Hammers (Drop Hammers)

Apply an impact load against work part - two types: Gravity drop hammers - impact energy from falling weight of a heavy ram Power drop hammers - accelerate the ram by pressurized air or steam Disadvantage: impact energy transmitted through anvil into floor of building Most commonly used for impression-die forging

Diagram showing details of a drop hammer for impression die forging

Forging Presses
Apply gradual pressure to accomplish compression operation - types:
Mechanical presses - converts rotation of drive motor into linear motion of ram Hydraulic presses - hydraulic piston actuates ram Screw presses - screw mechanism drives ram

Extrusion
Compression forming process in which the work metal is forced to flow through a die opening to produce a desired cross-sectional shape Process is similar to squeezing toothpaste out of a toothpaste tube In general, extrusion is used to produce long parts of uniform crosssections Two basic types of extrusion: Direct extrusion Indirect extrusion

Direct extrusion

Comments on Direct Extrusion

Also called forward extrusion As ram approaches die opening, a small portion of billet remains that cannot be forced through die opening This extra portion, called the butt, must be separated from extruded product by cutting it just beyond the die exit Starting billet cross section usually round, but final shape is determined by die opening

(a) Direct extrusion to produce a hollow or semi hollow cross-section; (b) hollow and (c) semi hollow cross- sections

Comments on Indirect Extrusion

Also called backward extrusion and reverse extrusion Limitations of indirect extrusion are imposed by the lower rigidity of hollow ram and difficulty in supporting extruded product as it exits die

Indirect extrusion to produce (a) a solid cross-section and (b) a hollow cross-section

General Advantages of Extrusion

Variety of shapes possible, especially in hot extrusion
Limitation: part cross-section must be uniform throughout length

Grain structure and strength enhanced in cold and warm extrusion Close tolerances possible, especially in cold extrusion In some operations, little or no waste of material

Hot vs. Cold Extrusion

Hot extrusion - prior heating of billet to above its recrystallization temperature
This reduces strength and increases ductility of the metal, permitting more size reductions and more complex shapes

Cold extrusion - generally used to produce discrete parts

The term impact extrusion is used to indicate high speed cold extrusion

A complex extruded cross-section for a heat sink (photo courtesy of Aluminum Company of America)

Wire and Bar Drawing

Cross-section of a bar, rod, or wire is reduced by pulling it through a die opening Similar to extrusion except work is pulled through die in drawing (it is pushed through in extrusion) Although drawing applies tensile stress, compression also plays a significant role since metal is squeezed as it passes through die opening

Drawing of bar, rod, or wire

Wire Drawing vs. Bar Drawing

Difference between bar drawing and wire drawing is stock size
Bar drawing - large diameter bar and rod stock Wire drawing - small diameter stock - wire sizes down to 0.03 mm (0.001 in.) are possible

Although the mechanics are the same, the methods, equipment, and even terminology are different

Drawing Practice and Products

Drawing practice:
Usually performed as cold working Most frequently used for round cross-sections

Products:
Wire: electrical wire; wire stock for fences, coat hangers, and shopping carts Rod stock for nails, screws, rivets, and springs Bar stock: metal bars for machining, forging, and other processes

Wire Drawing
Continuous drawing machines consisting of multiple draw dies (typically 4 to 12) separated by accumulating drums Each drum (capstan) provides proper force to draw wire stock through upstream die Each die provides a small reduction, so desired total reduction is achieved by the series Annealing sometimes required between dies

49 of wire Continuous drawing

Bar Drawing
Accomplished as a single draft operation - the stock is pulled through one die opening Beginning stock has large diameter and is a straight cylinder This necessitates a batch type operation

Hydraulically operated draw bench for drawing metal bars