Beruflich Dokumente
Kultur Dokumente
METAL WORK
Mechanical working process also known as metal
forming processes, are primary shaping processes in
which a mass of a metal or alloy is subjected to
mechanical force.
Under the shape of such forces, the shape and size
of metal piece undergo a change.
By mechanical processes, the given shape and size
of a machine part can be achieved with great
economy in material and time.
Metal forming is possible in case of such metals or
alloys are sufficiently malleable and ductile.
Frequently, work piece of material is not sufficiently
malleable and ductile ordinary at the room
temperature , but may become so when heated.
Thus we have both hot and cold metal forming
operation.
Cold Work
a) Rolling (Cold and Hot rolling)
Rolling Process
In this process, metals and alloys are plastically
deformed into semi finished and finished products
by being pressed between two rolls which are
rotating.
The metal initially pushed into the space between
two rolls, there after once the roll takes a bite into
the edge of material, the material gets pulled in by
Hot Rolling
Cold Rolling
Rolling Deffect
Rolling defects divide in to classes:
a) Surface defects
b) Structural defects
) Types of surface defects:
a) Rusting and scaling
b) Surface scratches
c) Surface cracks
) Types of structural defects:
a) Wavy edges
b) Zipper cracks
c) Edge cracks
d) Center split
e) Alligatoring
b) Wire Drawing
) Wire drawing is a simple process
) In this process, rods made of steel and non-ferrous
metals and alloys are pulled through conical dies
having a hole in centre.
) The included angle of the cone is kept between 8 to
24.
) As the material is pulled through the cone, it
undergoes plastic deformation and it gradually
undergoes a reduction in its diameter.
) At the same time, the length is increased
proportionately.
c) Tube Drawing
) The drawing process can also be used for tube
drawing.
) Tube drawing does not mean manufacturing a tube
from solid raw material.
) It means lengthening a tube reducing its diameter.
) Various arrangements used for tube drawing are
shown in figure.
Hot Working
a) Forge and Smith forge
) In forging, metals and alloys are deformed to the
specified shapes by application of repeated blows
from a hammer.
) It usually done hot; although sometimes cold forging
is also done.
) The raw material is usually a piece of a round or
square cross section slightly larger in volume than
the volume of the finished component.
) Shows the video:
Type of extrusions
Advantages of extrusion:
The complexity and range of parts which can
produced
The extrusion process is complete in one pass only.
Large diameter, hollow products, thin walled tubes
are easily to produced.
Good surface finish and excellent dimensional and
geometrical accuracy.
CASTING PROCESS
Manufacture of a machine part by heating a metal or
alloy above its melting point and pouring the liquid
metal/alloy in a cavity approximately of same shape
and size as the machine part is called casting
process.
After the liquid metal cools and solidifies, it acquires
the shape and size of the cavity and resembles the
finished product required.
The manufacture of a casting requires:
(a) Preparation of a pattern,
(b) Preparation of a mould with the help of the
pattern,
(c) Melting of metal or alloy in a furnace,
(d) Pouring of molten metal into mould cavity,
(e) Breaking the mould to retrieve the casting,
(f) Cleaning the casting and cutting off risers,
sand
Melting
Of metal
furnaces
c) Die casting
i. Hot die casting
HEAT TREATMENT
Heat treatment is a combination of heating and
cooling operations, timed and applied to a metal or
alloy in the solid state in a way that will produce
desired properties
The first step in the heat treatment of steel is to heat
the material to some temperature in or above the
critical range in order to form austenite.
Highly stressed materials produced by cold work
should be heated more slowly than stress-free
materials to avoid distortion.
The types of heat treatment
a) full annealing
a) Stress relief annealing
b) Spheroidizing
c) Normalizing
a)Full Annealing
) heat treating process used to soften previously coldworked metal by allowing it to recrystallize.
) The term annealing refers to a heat treatment in
which a material is exposed to an elevated
temperature for an extended time period and then
slowly cooled. Ordinarily, annealing is carried out to:
(1) relieve stresses (often introduced when coldworking the part) (2) increase softness, ductility and
toughness
(3) produce a desired microstructure
() Any annealing process consists of three stages:
1. heating to the desired temperature
2. holding or soaking at that temperature
3. slowly cooling, usually to room temperature
() Time is the important parameter in these procedures.
Process annealing is a heat treatment that is used to
negate the effects of cold work that is to soften and
c) Spheroidizing
) An
annealed
hypereutectoid
steel
with
a
microstructure of pearlite and a cementite network
will generally give poor machinability.
) Since cementite is hard and brittle, the cutting tool
cannot cut through these plates.
) A heat-treating process which will improve the
machinability is known as spheroidize annealing.
) This process will produce a spheroidal or globular
form of carbide in a ferritic matrix.
) Medium and high carbon steels having a
microstructure containing coarse pearlite may still be
too hard to conveniently machine or plastically
deform.
) These steels (and in fact, any steel) may be annealed
to develop the spheroidite structure.
d) Normalizing
) is an annealing heat treatment used to refine the
grains and produce a more uniform and desirable size
distribution.
) Normalizing is accomplished by heating the material
to a temperature above its upper critical temperature
(e.g.: just above 1333F for most fastener-related
steels).
) After sufficient time has been allowed for the alloy to
completely transform to austenite, the metal is
allowed to cool in the air.