TAKORADI POLYTECHNIC

GROUP E(2011) PRESENTATION ON FORMING PROCESS

NAMES 1. FRANCIS ADJEI TAWAIH 2. EBENEZER GYAMFI 3. EKOW DAVIES JOSEPH 4. ALFRED ANSAH 5. DAVID E. ANSAH 6. ISHMEAL O. COMMEY 7. ROBERT SOMETIAMAH

INDEX NO 07098397 07098325 07098346 07098311 07098363 07098399 07098382

OBJECTIVES
At the end of the lectures student should; 1. Describe the forms of supply of raw materials for casting, rolling, extrusion, forging, and pressing. 2. Describe with the aid of sketches the principles of casting, rolling, extrusion, forming, forging and pressing. 3. Select the special properties require of raw materials used in the processes 4. Select forming process given simple component.

INTRODUCTION
Hammering by hand was the first method used by our early ancestors to shape metals. Since the bronze age, about 4000 years ago. Humans have been melting metals, pouring them into moulds and pounding materials into new shapes. this process like all forming operations, does not involves cutting or shearing, rather it is a reshaping of the material.

FORMS OF SUPPLY OF RAW MATERIALS

The productive forming processes to which materials can be subjected to, and the consequent shapes and accuracy limits to which it is produced depends on the physical proprieties and other characteristics of the material. These factors often impose limitation, either on the form of supply or on the use, particular metal for a certain purpose. For example, in its solid state, cast iron is brittle at all temperatures and for this reason can be neither rolled nor drawn. If therefore, we required cast iron bar, we can obtain only short bars because it has to be cast into this form and the limitations of this process render the production of long bars almost impossible

Metals Cast iron Low and medium carbon steel

Forms of supply Shorts bars; hollow cylinder, cast plates, pipes Hot rolled bars,round,square,flate. Bright-drawn bar; round, square, hexagonal, rectangular. Bright-rolled flats and strip, drawn tubing black sheets, plate and strip, black tubing.

High-carbon steel

Black rolled bars of round, square flat, octagonal section. Flat strip and plate surface grounds to close limits of the thickness Bars; round, square, late, hexagonal etc. Powder and rod for brazing, miscellaneous standard water fittings.
Rolled and drawn bars Short cast sticks Rolled strip and sheet.

Brass

Bronze gunmetal

PROPERTIES REQUIRED OF A RAW MATERIAL USED IN THE FORMING PROCESS

Ductility: is the ability of a material to deform considerably under a tensile load before failure. Material having this properties can be formed into various shapes by bending, drawing,extruding,rolling. Malleability: is the ability of a material to be permanently deformed in compression without fracture; for example, by hammering, forging, pressing, rolling etc. this property is very similar to ductility.

Toughness: is the ability of a material to resist fracture, especially under applied force. Tough materials are capable of absorbing a large amount of impact energy without fracture and some can be repeatedly bent or twisted. Plasticity: is the propensity of a material to undergo permanent deformation under load. Fluidity: is the physical property of a substance that enables it to flow.

FORMING PROCESSES Forming is the process that involves the application of temperatures and pressures to change the shape and size of an object in solid phase.

I. II. III. IV. V. VI.

TYPES OF FORMING PROCESSES Casting Rolling Extruding Forging Pressing Drawing

CASTING
Casting is a manufacturing process by which liquid material is usually poured into a mould, which contains a hollow cavity of desired shape and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mould to complete the process. Casting is most often used for making complex shapes that would be otherwise difficult to make by other methods. TYPES OF CASTING 1. Sand casting 2. Die casting

SAND CASTING
It is the process in which molten metal is poured into a mould cavity formed out of sand. The cavity is contained in an aggregate housed in a box called the flask, which are typically made out of wood, sometimes metal. Sand casting is usually used to make large parts. see fig 1.

Fig 1 Sand casting

DIE CASTING
Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mould cavity. The mould cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to moulds during the process. TYPES OF DIE CASTING 1. Pressure die casting 2. Gravity die casting

PRESSURE DIE CASTING

Pressure die casting is a process where metal is melted and forced into steel dies. The metal hardens into the desired shape. Molten metal is injected into a die cavity through a channel by movement of a plunger. After a preset solidification time, the plunger reverses direction, the part is ejected, and the machine is ready for the next cycle.

Types of pressure die casting

1. Cold chamber pressure die casting 2. Hot chamber pressure die casting

COLD CHAMBER PRESSURE DIE CASTING

These are used when the casting alloy cannot be used in hot-chamber machines. The process for these machines start with melting the metal in a separate furnace. Then a precise amount of molten metal is transported to the coldchamber machine where it is fed into an unheated shot chamber (or injection cylinder). This shot is then driven into the die by a hydraulic or mechanical piston. see fig 2

Fig 2

Cold chamber pressure die casting

HOT CHAMBER PRESSURE DIE CASTING

Hot-chamber machines, also known as gooseneck machines, rely upon a pool of molten metal to feed the die. At the beginning of the cycle the piston of the machine is retracted, which allows the molten metal to fill the "gooseneck". The pneumatic or hydraulic powered piston then forces this metal out of the gooseneck into the die. see fig 3

Fig 3 Hot chamber Pressure die casting

GRAVITY DIE CASTING

Gravity Die Casting uses the force of gravity, instead of high pressure means, to fill a permanent mold, or die, with molten material. see fig 4

fig 4

Gravity die casting

ROLLING
It is the process in which a set of cylindrical rollers is used to reduced the thickness of a plate or sheet. The length of the rolled sheet increases if the width or thickness of the rolls is large. The rollers or rolls are rotating in opposite direction pulling the materials in and reducing its thickness. Rolling is considered to be a semi continues process rather than a discrete manufacturing process.

HOT ROLLING
Hot rolling is a metalworking process that occurs above the recrystallization temperature of the material. After the grains deform during processing, they recrystallize, which maintains an equiaxed microstructure and prevents the metal from work hardening. The starting material is usually large pieces of metal, such as slabs, blooms, and billets. See fig 5

fig 5 Hot rolling

COLD ROLLING
Cold rolling occurs with the metal below its recrystallization temperature (usually at room temperature), which increases the strength. Its also improves the surface finish and holds tighter tolerances. Commonly cold-rolled products include sheets, strips, bars, and rods; these products are usually smaller than the same products that are hot rolled.

FORMS OF COLD ROLLING

1. Four high mill 2. Cluster mill

FOUR HIGH ROLLING MILL

It has a roll stand with four parallel rolls one above the other. The top and the bottom rolls rotate in opposite direction as do the two middle rolls. The two middle are smaller in size than the top and bottom rolls which are called backup rolls for providing the necessary rigidity to the smaller rolls. See fig 6

fig 6

Four high rolling mill

CLUSTER ROLLING MILLS: It is a special type of four high rolling mill in which each of the two working rolls is backup by two or more of the larger backup rolls for rolling hard in materials. It may be necessary to employ work rolls of a very small diameter but of considerable length. In such cases adequate of the working rolls can be obtained by using a cluster mill. See fig 7.

fig 7

EXTRUSION
Is the process in which material is compressed in a chamber and the deformed material is forced to flow through the die. The die opening corresponds to the cross section of the required product. It is basically a hot working process, however, for softer materials cold extrusion is also performed.

TYPES OF EXTRUSION PROCESS

1. Direct extrusion 2. Indirect extrusion

DIRECT EXTRUSION
In direct extrusion metal flows in the same direction as that of the ram. Because of the relative motion between the heated billet and the chamber walls, friction is severe and is reduced by using molten glass as a lubricant in case of steels at higher temperatures. At lower temperatures, oils with graphite powder is used for lubrication. see fig 8

fig 8

Direct extrusion

INDIRECT EXTRUSION In indirect extrusion process metal flows in the opposite direction of the ram. It is more efficient since it reduces friction losses considerably. The process, however, is not used extensively because it restricts the length of the extruded component. see fig 9

fig 9

Indirect extrusion

FORGING
Forging is the process of deforming a material between two dies to achieve desired configuration. Depending upon complexity of the part forging is carried out as 1. open die forging and 2. closed die forging.

OPEN DIE FORGING In open die forging, the metal is compressed by repeated blows by a mechanical hammer and shape is manipulated manually. see fig 10

fig 10 Open die forging

CLOSE DIE FORGING

In closed die forging, the desired configuration is obtained by squeezing the work piece between two shaped and closed dies. On squeezing the die cavity gets completely filled and excess material comes out around the periphery of the die as flash which is later trimmed. see fig 11

fig 11 Close die forging

PRESSING
Pressing is the shaping of sheet metal, ferrous and non-ferrous metals in a die of the desires shape, under a force. The material must be in the annealed condition before pressing. When a number of pressing operation have to be carried out to achieved the final desired shape, the material will invariably requires inter stage annealing to ensure tear and ripple-free products. See fig 12

SKETCH ON PRESS FORMING

fig 12

press forming

DRAWING
It is the process of reducing the size and shape of a material to a desire shape and size by pulling it through a die. Large quantities of wires, rods, tubes and other sections are produced by drawing process which is basically a cold working process. In a typical wire drawing operation, one end of the wire is reduced and passed through the opening of the die, gripped and pulled to reduce its diameter. see fig 13

fig 13

Drawing

WIRE DRAWING
By successive drawing operation through dies of reducing diameter the wire can be reduced to a very small diameter. Annealing before each drawing operation permits large area reduction. tungsten Carbide dies are used to for drawing hard wires, and diamond dies is the choice for fine wires. see fig 14

fig 14 Wire drawing

CHARATERISTICS OF FORMING PROCESS

1. The work piece is completely or partially subjected to plastic deformation during the forming operation; that is, it is plasticized. 2. Little or no material is removed during the forming process. 3. The microstructure of the as-cast work piece is broken down by the plastic deformation. 4. The final component, or product, made by metal forming usually will have better mechanical properties than a similar product manufactured by machining 5. During cold deformation, mechanical properties, such as the yield strength and tensile strength, will increase because of the accumulation of plastic strain in the material.

1. 2. 3. 4.

ADVANTAGES OF FORMING PROCESS High material utilization, hence high energy conservation. High productive with short production time. High dimensional and shape accuracy within certain tolerances. Superior mechanical material properties.

DISADVANTAGES OF FORMING PROCESS

1. The limited formability of metals restrict the range of product geometry 2. The process usually require a high level of engineering including analysis and also extended experience.

VIDEO ON DIE CASTING PROCESS

BENEFITS OF DIE CASTING PROCESS 1. High degree of design complexity and accuracy. 2. Excellent smooth surface finish. 3. Less material is squandering because the metal is selected to fit the desired shape with as little waste as possible. 4. High production

CONCLUSION Having studied forming process, we have known the forms of supply of raw materials for various operation. Example; short bars, hot rolled bars, bright drawn bars, bright rolled flats and stripes etc. Also the properties required of the raw material such as toughness, malleability, plasticity, fluidity etc. Finally we discuss the principle of the processes with relevant sketches.

REFERENCES
1. Chapman W. A. J (1976) Workshop Technology Part 3. Edward Arnold( Publishers) Ltd London. 2. Komacek S. A, Lawson A.E,. Horton A.C (1990), manufacturing technology, McGraw-Hill Pub Ltd U.S.A 3. Society of manufacturing engineering (www.sme.org)