Chapter Three Week 6

15/7/2014
Diploma in Mechanical Engineering (Material)
JF 302 MATERIAL TECHNOLOGY 1

www.pis.edu.my
CLO 2 : Synthesis course knowledge into an effective

course assignment and present technical findings
both orally and in writing.
Week 6
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cold work
Mechanical Working
Mechanical working of a metal is simply plastic deformation performed to
change dimensions, properties and surface condition.
It is worked for three purposes:
a. To produce a particular shape
b. To break down the cast structure and improve the properties of the metal
c. To impart a desirable dimension and surface finish
Mechanical working of metals may be classified into:
i. Cold working
ii. Hot working
casting process
Cold working
Heat treatment of steels
Hot working
Cold working of a metal is carried out Hot working of a metal is carried out
below its re-crystallization
above its re-crystallization
temperature.
temperature but below its melting
point.
Metal working performs above room
temperature that the metal does not
work harden.
Understand hot work
Describe the heat treatment of steels
hot work
casting process
Understand cold work
Describe the casting process
cold work
hot work
cold work
hot work
casting process
What is re-crystallization
temperature?
Think critically 3.0
Plastic deformation of a metal which

results in strain hardening. It usually
involves working at room
temperature.
15/7/2014
cold work
hot work
casting process
What is re-crystallization
temperature?
cold work
hot work
casting process
Cold working
Hot working
Cold working distorts grain structure

of the metals.
Hot working refines grain structure of

the metals. The coarse columnar
dendrites of cast metal are refined to
smaller grains and improve the
mechanical properties of the
component.
Good surface finish is obtained.
Surface finish of hot worked metal is

not as good as with cold working,
because of oxidation and scaling.
The approximate minimum temperature

at which complete re-crystallization of a
cold worked metal occurs within a
specified time.
cold work
hot work
casting process
cold work
hot work
casting process
Cold working
Hot working
Purposes of Cold working
Excessive cold working gives rise to

the formation and propagation of
cracks in the metal.
Defects in the metal, such as holes,

internal porosity, cracks; when they
get welded up during hot working.
The loss of ductility during cold

working has a useful side effect in
machining. With less ductility, the
chips break more readily and
facilitate the cutting operation.
During hot working, self annealing

occurs and re-crystallization takes
place immediately following plastic
deformation. This will cause to loss of
ductility.
1. To obtain thinner work piece

1. To improve properties of the
2. To obtain good surface finish
metal, as compared to those in
3. To obtain greater dimensional
cast condition
accuracy
2. To produce raw material to be
4. To improve mechanical properties
used for subsequent cold working
operations
cold work
Cold working
Advantages:
hot work
casting process
Hot working
Advantages:
1. Increase:
1. It does not affect tensile strength,
a. Ultimate tensile strength
hardness, corrosion resistance for
b. Yield strength
work piece.
c. Hardness
2. It promotes uniformly of work
d. Fatigue strength
piece by facilitating diffusion of
e. Residual stresses
alloy constituents and breaks up
2. No heating is required.
the brittle films or impurities in
3. It is more economical than hot
metals.
working for certain ductile metals.
Purposes of Hot working
cold work
hot work
casting process
Cold working
Limitations :
Hot working
Limitations :
1. Possess less ductility

2. Strain hardening occurs
3. Metal surface must be clean and
scale free before cold working
4. Higher forces are required for
deformation than hot working
1. Oxide forms rapidly on metal

surface
2. Surface scaling of the product
3. Surface decarburization
4. The volumetric expansion of the
work piece during heating and its
contraction during cooling
preclude the accurate final
dimension
15/7/2014
cold work
hot work
casting process
What is the effect of cold working on

the mechanical properties of copper?
Think critically 3.0(a)
cold work
hot work
casting process
What is the effect of cold working on

the mechanical properties of copper?
Think critically 3.0(a)
As the percent cold work increases,

both the yield strength and the tensile
strength increase. However, the
ductility decreases and approaches
zero.
The metal will break if more cold work
is attempted.
cold work
hot work
casting process
cold work
hot work
casting process
ROLLING
Cold working processes
Hot working process
1. Rolling
2. Wire and tube drawing
1.
2.
3.
4.
Hot Rolling
Forging
Extrusion
Welding
Fig 3.0 Rolling process
cold work
hot work
casting process
Principle of Operation:
A pair of cylindrical rollers made of iron or steel
rotate in opposite direction with a gap in between.
The worked piece is entered into the gap and
passes between the rollers. It is squeezed and its
cross section is reduced.
ROLLING
cold work
hot work
casting process
ROLLING
Cold rolling is applied to sheet or plate to make it
thinner, better surface finish, maintain an accuracy
dimension and increase the strength and hardness.
Hot rolling is used to convert ingots into smaller
sections known as billets. It is used to produce
plate, sheet and also rods, bars and various
structural shapes through rollers at certain
temperature.
Rolling temperature:
Hot rolling is carried out at tempt. above 0.7Tm
(where Tm is the melting point of the metal in C)
1000C for mild steel and 450C for aluminium.
Fig 3.1 Cold and hot rolling
15/7/2014
cold work
hot work
casting process
ROLLING
Advantages :
i. High speed of rolling
ii. Economy of the process
iii. Refine the cast coarse crystalline structure and
eliminate the gas pockets and shrinkage cavities.
cold work
WIRE AND
TUBE
DRAWING
Limitations :
i. Non-uniform surface finish of the hot rolled metals
ii. The degree of size or dimensional control
attainable in hot rolling is not narrowly precise.
hot work
casting process
Wire drawing involves reducing the diameter of a
rod or wire by passing through a series of drawing
dies or plates.
Tube drawing involves reducing the cross section
and wall thickness through a draw die.
Fig 3.2 Wire and tube drawing
cold work
WIRE AND
TUBE
DRAWING
hot work
casting process
Wire drawing:
The finished wire is coiled onto a motor driven
block. The dies are manufactured from hard
material, for example tungsten carbide. Diamonds
dies are used for small diameter wire. Soap is used
for lubrication. If large diameter reductions are
required, the rod is progressively drawn through
several
stages
of
dies
and
blocks.
cold work
WIRE AND
TUBE
DRAWING
hot work
casting process
Tube drawing:
A draw bench is used to pull the tube through a
drawing die. One end of the tube to be drawn is
collapsed and fed through the die. This end is then
clamped to a travelling carriage. The carriage is
moved away from the die either mechanical or
hydraulically traction. In practice several tubes may
be drawn in parallel to increase productivity.
Wire can be extruded at speeds of up to

2000m/min.
cold work
hot work
casting process
cold work
hot work
casting process
FORGING
Fig 3.3 Forging process
Forging is the shaping of metal either by impact or
steady compression between a hammer and an
anvil. Usually the metal is heated to increase its
plasticity.
Working:
a. Metal to be forged is first formed into bars or
blocks, called billets.
b. The billets are heated to permit an easy flow of
the metal for shaping purposes before forging.
c. Hammer rests on the anvil and cause the metal
to change shape.
When do the cold forging process is

used?
15/7/2014
cold work
hot work
casting process
cold work
hot work
casting process
EXTRUCTION
When do the cold forging process is

used?
Extrusion is a metal working process that produces
long lengths of uniform cross sectional area from a
metal billet by causing the latter to flow under
hydrostatic pressure through a restricted die.
Working:
a. A heated cylindrical billet is placed in the
container and forced out through a steel die by a
ram.
b. The metal takes in cross section the shape of the
die.
It is necessary to:
a. develop strength and hardness in a
component
b. have bright and clean surface
c. eliminate forging scale
d. eliminate decarburizing
Fig 3.4 Extrusion process
cold work
hot work
casting process
What are the two types of hot

extrusion process? Discuss briefly.
cold work
hot work
casting process
What are the two types of hot

extrusion process? Discuss briefly.
a. Direct extrusion
b. Indirect extrusion
cold work
hot work
casting process
a. Direct extrusion
cold work
hot work
casting process
b. Indirect extrusion
i. A hot billet is placed within the container

ii. A ram forces hot billet through the die opening,
producing the extruded product.
i. The billet remains stationary while the die is

pushed into the billet by the hallow ram through
which the extrusion takes place
ii. It does not require as much force as direct
extrusion because no force is required to move
the hot billet inside the container.
15/7/2014
cold work
hot work
casting process
HOT
EXTRUCTION
cold work
hot work
casting process
List four typical types of cold

extrusion processes.
a.
b.
c.
d.
casting process
List four typical types of cold

extrusion processes.
cold work
hot work
Hooker extrusion
Hydrostatic extrusion
Impact extrusion
Cold extrusion forging
cold work
hot work
casting process
Name the following

metal working
processes:

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15/7/2014

Diploma in Mechanical Engineering (Material)

JF 302 MATERIAL TECHNOLOGY 1

CLO 2 : Synthesis course knowledge into an effective

peneraju ilmu sejagat

peneraju ilmu sejagat

peneraju ilmu sejagat

peneraju ilmu sejagat

Heat treatment of steels

Heat treatment of steels

Understand hot work

Describe the heat treatment of steels

Understand cold work

Describe the casting process

Heat treatment of steels

Think critically 3.0

Plastic deformation of a metal which

peneraju ilmu sejagat

peneraju ilmu sejagat

Heat treatment of steels

Think critically 3.0

Cold working distorts grain structure

Hot working refines grain structure of

Good surface finish is obtained.

Surface finish of hot worked metal is

The approximate minimum temperature

peneraju ilmu sejagat

Heat treatment of steels

peneraju ilmu sejagat

Heat treatment of steels

Heat treatment of steels

Purposes of Cold working

Excessive cold working gives rise to

Defects in the metal, such as holes,

The loss of ductility during cold

During hot working, self annealing

1. To obtain thinner work piece

peneraju ilmu sejagat

peneraju ilmu sejagat

Heat treatment of steels

peneraju ilmu sejagat

Purposes of Hot working

Heat treatment of steels

1. Possess less ductility

1. Oxide forms rapidly on metal

peneraju ilmu sejagat

Heat treatment of steels

What is the effect of cold working on

Think critically 3.0(a)

Heat treatment of steels

What is the effect of cold working on

Think critically 3.0(a)

As the percent cold work increases,

peneraju ilmu sejagat

peneraju ilmu sejagat

Heat treatment of steels

Heat treatment of steels

Hot working process

Fig 3.0 Rolling process

peneraju ilmu sejagat

peneraju ilmu sejagat

Heat treatment of steels

Heat treatment of steels

peneraju ilmu sejagat