Lesson Objectives:

Todays lesson objectives: Shape rolling and other rolling processes Introduction to forging processes for metals Introduction to forging operations

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Rolling of Metals

Shape-rolling Operations
In addition to flat rolling, various

shapes can be produced by shape rolling. Straight and long structural shapes, such as solid bars (with various crosssections), channels, I-beams, railroad rails are rolled by passing the stock through a set of specially designed rolls.
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Shape Rolling
Stages in the shape rolling of an Hsection part. Various other structural sections, such as channels and I-beams, are also rolled by this kind of process.

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Ring Rolling
A thick ring is expanded into a large

diameter ring with a reduced cross-section. The ring is placed between two rolls closer together, one of which is driven and its thickness is reduced by bringing the rolls closer together as they rotate. Applications: ball and roller bearing races, steel tires for railroad wheels, and rings for pipes, pressure vessels, and rotating machinery . Page 6 BMM 3643

Ring Rolling (cont.)

Advantages: material savings, ideal grain

orientation, strengthening through cold working

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

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Ring-Rolling

(a) Schematic illustration of a ring-rolling operation. Thickness reduction results in an increase in the part diameter. (b) Examples of cross-sections that can be formed by ring rolling.

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Thread Rolling
It is a process in a cold-forming process by

which straight or tapered threads are formed on round rods, by passing them between dies. 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

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Thread-Rolling
Thread-rolling processes: (a) and (c) reciprocating flat dies; (b) tworoller dies. Threaded fasteners, such as bolts, are made economically by these processes, at high rates of production.

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Thread-Rolling

(a) Features of a machined or rolled thread. (b) Grain flow in machined and rolled threads. Unlike machining, which cuts through the grains of the metal, the rolling of threads causes improved strength, because of cold working and favorable grain flow.
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Defects in Flat Rolling

Few defects occurred in flat rolling

process may not only degrade surface appearance but may adversely affect the strength, formability and etc. Examples of defects in flat rolling are:

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Defects in Flat Rolling

Wavy edges the strip is thinner along its edges that its centre, thus the edges elongate more than centre.

Cracks result of poor material ductility at the rolling temperature

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Defects in Flat Rolling

Edge cracks poor quality of materials at the edges

Alligatoring complex phenomenon caused by nonuniform bulk deformation process or presence of defects in the original materials
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Forging of Metals

Forging
It is a process in which the workpiece is

shaped by compressive forces applied through various dies and tools. Oldest metalworking operation Simple forging operations can be performed with a heavy hand hammer, traditionally done by blacksmiths.

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Forging
Most forgings, require a set of dies and

a press or a forging hammer. Forging operations produce discrete parts. Typical forged products are bolts and rivets, connecting rods, shafts for turbines, gears, hand tools, aircraft components, etc.
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Forging
(a) (b)

Figure 14.1 (a) Schematic illustration of the steps involved in forging a bevel gear with a shaft. Source: Forging Industry Association. (b) Landing-gear components for the C5A and C5B transport aircraft, made by forging. Source: Wyman-Gordon Company.
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Characteristics of Forging Processes

TABLE 14.1 Process Open die Advantages Simple, inexpensive dies; useful for small quantities; wide range of sizes available; good strength characteristics Relatively good utilization of material; generally better properties than open-die forgings; good dimensional accuracy; high production rates; good reproducibility Low die costs; high production rates Requires much less machining than blocker type; high production rates; good utilization of material Close tolerances; machining often unnecessary; very good material utilization; very thin webs and flanges possible Limitations Limited to simple shapes; difficult to hold close tolerances; machining to final shape necessary; low production rate; relatively poor utilization of material; high degree of skill required High die cost for small quantities; machining often necessary

Closed die

Blocker type Conventional type

Machining to final shape necessary; thick webs and large fillets necessary Somewhat higher die cost than blocker type

Precision type

Requires high forces, intricate dies, and provision for removing forging from dies

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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

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Classification of Forging Operations (cont.)

Impact vs. press forging: Forge hammer - applies an impact load Forge press - applies gradual pressure

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Thats all for today.. Any questions??

IQ + EQ + SQ = TQ
Thank You for coming and see you again..