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PROCESSES
IN METALWORKING
BULKDEFORMATION
Metalformingoperationswhichcausesignificant
shape
changeby deformation in metalpartswhoseinitial
is bulk ratherthansheet
o Performed
as cold,warm,andhotworkingoperations
IMPORTANCE
OF BULKDEFORMATION
o In hotworking,
significant
shapechangecanbe
accomplished
o In coldworking,strength
canbe increased
duringshape
change
FOURBASICBULKDEFORMATION
PROCESSES
i. Rolling- slabor plateis squeezed
between
opposing
rolls
Directionof workflow
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The rollingprocess(specifically,
flat rolling)
THE ROLLS
The rotatingrollsperformtwo mainfunctions:
o Simultaneously
squeezethe workto reducecross
section
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TYPESOF ROLLING
o By geometryof work:
. Flat rolling- usedto reducethicknessof a rectangular
cross-section
. Shaperolling- a squarecross-section is formedinto a
shapesuchas an l-beam
o By temperature
of work:
. Hot Rolling- mostcommondue to the largeamountof
deformationrequired
. Coldrolling- producesfinishedsheetand platestock
Structumlshapes
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7 ct
Bars, rods
VARIOUSCONFIGURATIONS
OF
ROLLING
MILLS
-%
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(b)
(b) 3-highrollingmill
VARIOUSCONFIGURATIONS
OF ROLLIN
MILLS
(c)four-high
rollingmill
VARIOUSCONFIGURATIONS
OF
ROLLINGMILLS
(d)
(d) clustermill
VARIOUSCONFIGURATIONS
OF ROLLIN
MILLS
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(e)tandemrolling
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THREADROLLING
Bulkdeformationprocessusedto form threadson cylindricalpartsby
them betweentwo dies
Advantagesover threadcutting(machining):
. Higherproductionrates
. Bettermaterialutilization
. Strongerthreadsdue to work hardening
. Betterfatigueresistancedue to compressive
stressesintroducedp"v
rolling
THREADROLLING
Finished pan
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Moving di€
Threadrollingwithflatdies: .'!t\\i\:i:,
o As thick-walledring is compressed,deformedmetalelongates,
causingdiameterof ringto be enlarged
o Advantages:materialsavings,idealgrainorientation, a1#
strengthening
throughcoldworking
RINGROLLING
o In addition,
basicmetalsindustries
useforgingto establish
bgsic
formof largecomponents thataresubsequently machined to riq;
finalshapeandsize
CLASSIFICATION
OF FORGING
OPERATIONS
o Coldvs. hotforging:
. Hot or warm forging - mostcommon,due to the
significantdeformationand the needto reducestrength
and increaseductilityof workmetal
. Cold forging - advantageis increasedstrengththat
resultsfromstrainhardening
o lmpactvs. pressforging:
. Forge hammer - appliesan impactload
. Forge press - appliesgradualpressure
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TYPESOF FORGING
DIES
1, Open-die forging - work is compressedbetweentwo flat dies,
allowingmetalto flow laterallywithoutconstraint
1. OPEN.DIEFORGING
Compressionof workpartwith cylindricalcross-section
betweentwo flat dies
o Similarto compressiontest
o Deformation operationreducesheightand increases
diameterof work
o Common names includeupsettingor upsef forging
2. IMPRESSION.DIE
FORGING
Compressionof workpartby dies with inverseof desiredpart shape
o Flash is formed by metalthat flows beyonddie cavity into small gap
betweendie plates
o Flash must be latertrimmedfrom part, but it servesan important
functionduringcompression:
. As flash forms,frictionresistscontinuedmetalflow into gap,
constrainingmaterialto fill die cavity
. In hot forging,metalflow is furtherrestrictedby coolingagainstdie
plates
IMPRESSION.DIE
FORGING
ADVANTAGESAND LIMITATIONS
Flashlessforging:
(i) just beforeinitialcontactwith workpiece,
(2) partialcompression,and
(3) final punchand die closure
FORGTNG (DROP
HAMMERS
HAMMERS)
o Apply an impact load againstworkpart - two types:
. Gravitydrop hammers- impactenergyfrom fallingweight of a
ram
. Power drop hammers- acceleratethe ram by pressurizedair or
steam
o Disadvantage:impactenergytransmitted throughanvil intofloor of
building
o Mostcommonlyusedfor impression-die forging
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FORGING
PRESSES
o Applygradualpressure
to accomplish
compression
operation- types:
. Mechanicalpresses- convertsrotationof drivemotor
intolinearmotionof ram
. Hydraulicpresses- hydraulicpistonactuatesram
. Screwpresses- screwmechanismdrivesram
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III.EXTRUSION
Compressionformingprocessin whichthe work metalis forcedto flow
througha die openingto producea desiredcross-sectional
shape
Wht;.
Directextrusion u*,
COMMENTS
ON DIRECTEXTRUSION
o Also called forward extrusion
o As ram approachesdie opening,a smallportionof billetremainsthat
cannotbe forcedthroughdie opening
o This extra portion,called the butt, must be separatedfrom extruded
productby cuttingit just beyondthe die exit
o Startingbilletcrosssectionusuallyround,butfinal shape is determi
by die opening
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(a) Directextrusionto producea hollowor semi-hollowcross-section;(b) ,.-:,,1
hollowand (c) semi-hollowcross-sections
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COMMENTSON INDIRECTEXTRUSION
o Also called backwardextrusionandreverse extrusion
o Limitationsof indirectextrusionare imposedby the lowerrigidityof
hollowram and difficultyin supportingextrudedproductas it exits
die
lndirectextrusionto oroduce
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HOTVS. COLDEXTRUSION
o Hot extrusion- priorheatingof billetto aboveits
Iizationtemperature
recrystal
. This reducesstrengthand increases
ductilityof the
metal,permitting
moresizereductions and more
complexshapes
o Coldextrusion- generallyusedto producediscrete
parts
. The termimpactextrusionis usedto indicatehigh
speedcoldextrusion
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A complexextrudedcross-section
for a heatsink
(photocourtesy
of AluminumCompanyof America)..__
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AND PRODUCTS
DRAWINGPRACTICE
o Drawingpractice:
. Usuallyperformedas coldworking
. Mostfrequentlyusedfor roundcross-sections
o Products:
. Wire'.electricalwire;wire stockfor fences,coat hangers,and
shoppingcarts
. Rodsfockfor nails,screws,rivets,and springs
. Bar sfock metalbarsfor machining, forging,and other
processes
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WIREDRAWING
o Continuousdrawingmachinesconsistingof multipledraw dies
(typically4Io 12) separatedby accumulating
drums
. Each drum (capsfan)providesproperforce to draw wire stock
throughupstreamdie
. Eachdie providesa smallreduction,so desiredtotal reductionis
achievedby the series
. Annealingsometimesrequiredbetweendies
BAR DRAWING
o Accomplished as a smg/e-draft - the stock
operation
is pulledthroughonedieopening
o Beginning stockhaslargediameter
andis a straight
cylinder
o Thisnecessitates a batchtypeoperation
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