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ITS
Industrial Engineering
• Yield Strength
• Ductility
• Malleability
• Machinability
• Stiffness
• Toughness
• Creep
Reminder
Industrial Engineering ITS
1. Bulk deformation
– Rolling
– Forging
– Extrusion
– Wire and bar drawing
2. Sheet metalworking
– Bending
– Deep drawing
– Cutting
– Miscellaneous processes
Bulk Deformation Processes
Industrial Engineering ITS
Rolling Mills
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Rolling process
Rolling Mills Configuration
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(a)two-high (b)three-high (c) four-high (d) cluster mill (e) tandem rolling mill
Other Rolling Processes(1)
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• Thread rolling
– Cold rolling
– Production rate: 8 unit/sec
Other Rolling Processes (2)
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• Ring rolling
– Hot rolling for large ring diameter
– Cold rolling for small ring diameter
Other rolling Processes (3)
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• Roll piercing
– Hot rolling
– For making thick pipe
– Rotary tube piercing
Rolling Defects
a. Waviness
– Improper roller speeds
b. Zipper cracks
– Too much rolling in center
c. Edge cracks
– Too much rolling on outside
d. Alligatoring
– Too much induced tensile
stress in the part, or defects
Forging
Industrial Engineering ITS
Open-Die Forging
Open Die Forging Defects
• Fracture -
– exhausted ductility
– Inter granular fracture in
hot working
• Barreling - Friction
• Solution -
– limited deformation per
step
– Process anneal between
steps
Impression-Die Forging
Industrial Engineering ITS
Forging Machines
Extrusion
Industrial Engineering ITS
• Hot extrusion
– Material: aluminum, copper, magnesium, zinc.
– Reduces strength and increase ductility of metal, more
extreme size reduction, and more complex shapes, increase
ram
– Lubrication is critical
• Cold extrusion
– Material: low carbon steel, stainless steel
– Increase strength (strain hardening), accuracy of tolerance
Types of Extrusion
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(a) Centerburst
(b) Piping/tailpipe, fishtailing
(c) Surface cracking
Wire and Bar Drawing
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Drawing Equipment
Tube Drawing (1)
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• With mandrel
– (a) fixed mandrel (b) floating plug
Industrial Engineering ITS