Beruflich Dokumente
Kultur Dokumente
Todays lesson objectives: Shape rolling and other rolling processes Introduction to forging processes for metals Introduction to forging operations
BMM 3643
Page 2
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.
BMM 3643
Page 4
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.
BMM 3643
Page 5
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
BMM 3643
Page 7
Ring rolling used to reduce the wall thickness and increase the diameter of a ring: (1) start, and (2) completion of process
BMM 3643
Page 8
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.
BMM 3643
Page 9
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
BMM 3643
Page 10
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.
BMM 3643
Page 11
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.
BMM 3643
Page 12
process may not only degrade surface appearance but may adversely affect the strength, formability and etc. Examples of defects in flat rolling are:
BMM 3643
Page 13
Wavy edges the strip is thinner along its edges that its centre, thus the edges elongate more than centre.
BMM 3643
Alligatoring complex phenomenon caused by nonuniform bulk deformation process or presence of defects in the original materials
BMM 3643
Page 15
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.
BMM 3643
Page 17
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.
BMM 3643
Page 18
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.
BMM 3643
Page 19
Closed die
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
BMM 3643
Page 20
BMM 3643
Page 21
BMM 3643
Page 22
IQ + EQ + SQ = TQ
Thank You for coming and see you again..