1) Die wear from abrasion and adhesion is the most frequent cause of part quality issues in hot forming processes like forging, extrusion, and rolling. Mechanical fatigue, plastic deformation, and thermal fatigue are also common issues.
2) Catastrophic die failure poses the most severe risk, followed by part defects and different types of die breakage.
3) Proper die material selection and coatings can improve die life by increasing hardness, wear and fatigue resistance at high temperatures. Process factors like temperature control and lubrication also impact die life.
Hot working and cold working of metals – Forging processes – Open, impression and closed die forging – Types of Forging Machines – Typical forging operations. Rolling of metals– Types of Rolling – Flat strip rolling – shape rolling operations – Defects in rolled parts. Principle of rod and wire drawing – Tube drawing – Principles and types of Extrusion – Hot and Cold extrusion.
Mumbai University
Mechanical engineering
SEM III
Material Technology
Module 1.4
Strain Hardening:
Definition importance of strain hardening, Dislocation theory of strain hardening, Effect of strain hardening on engineering behaviour of materials, Recrystallization Annealing: stages of recrystallization annealing and factors affecting it
Steel Hot Rolling, Hot Rolling of Steel, Metal Rolling, Metal Forming Process...Ajjay Kumar Gupta
Steel Hot Rolling, Hot Rolling of Steel, Metal Rolling, Metal Forming Process, Steel Rolling Process, Metalworking, Flat Rolling Fundamentals, Physical Metallurgy, Hot Rolled Steel, Rolling Mills (Pre-Treatment of Hot Metal, Heat Treatments for Hot-Rolled Products, Steelmaking Refractories, Refining of Stainless Steels, Steel Heating for Hot Rolling, Oxygen Steelmaking Processes)
Rolling of steel is one of the most important manufacturing processes for steel. It is usually the first step in the processing of steel after it is made and cast either in Ingot or continuous cast product in a steel melting shop. Hot rolling is used mainly to produce sheet metal or simple cross sections, such as rail tracks.
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Steel Hot Rolling, Hot Rolling of Steel, Metal Rolling, Metal Forming Process, Steel Rolling Process, Metalworking, Flat Rolling Fundamentals, Physical Metallurgy, Hot Rolled Steel, Rolling Mills, Pre-Treatment of Hot Metal, Heat Treatments for Hot-Rolled Products, Steelmaking Refractories, Refining of Stainless Steels, Steel Heating for Hot Rolling, Oxygen Steelmaking Processes, Best small and cottage scale industries, Business guidance for steel rolling industry, Business Plan for a Startup Business, Business plan for steel rolling mill, Business start-up, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot rolling mill process, Hot Rolling Mill, Hot Rolling mill, Hot Strip Mill, How is Steel Produced, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Indian Steel Industry, Industrial steel rolling mill, Modern small and cottage scale industries, Modern steel making technology, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Process & Applications, Process of steelmaking, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Project for startups, Rod and Bar Rolling, Rod and bar rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling process, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Small Start-up Business Project, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel Business, Starting a Steel rolling Business, Starting Steel Mini Mill, Start-up Business Plan for steel rolling, Startup Project for steel rolling business
Processes based on fluidity and solidification, or simply “casting”, include manufacturing techniques whereby molten material is poured or forced into a mould and allowed to harden. Appropriate variants of this technique are particularly suitable for the economical production of complex shapes, ranging from mass-produced parts for the automotive industry to one-of-a-kind production of jewellery or massive machinery.
Concepts of rolling, annealing, quenching, drawing, cold working, hot working...Talha Saleem
pictorial Concepts of rolling, annealing, quenching, drawing, cold working, hot working and forging by simple diagrams.
its just basics. (no explanation )
Characterization and processing of friction stir welding on copper weldseSAT Journals
Abstract FSW(Friction Stir Welding) is a welding technology will be a part of different metals with sensible properties. During this paper, fsw attachment b/n steel, aluminum and copper plates with thicknesses of 3 millimeter was welded. Here we tend to had considered completely different completely different} materials with different combinations i.e copper and copper, copper and aluminum, aluminum & stainless steel, stainless steel & copper. Friction Stir Welding experiments were employed to get the good wieldable properties by maintaining the rpm speeds to 1120 revolutions per minute and attachment speed within the limit of 14-112 mm/min and here we can adjust the pin profile of the location respect to the line butt. Micro struc analysis can be done for examine the parent and the welded material. Cutting and sectioning of the welded pieces for metallographic analysis of the planes which are perpendicular for the attachment and the travelling direction & which is parallel to the friction welding was done. Here the mechanical properties of welding which was were determined by employing the same standard micro hardness and also tensile hardness testing and finding the maximum elongation of the metals to the properties of fsw. From experimental fsw process it can be found the pin profile and also the rotational speed, feed is an important in manufacturing of free welds in fsw of aluminum, copper and steel. Key Words: FSW, Aluminum, copper, stainless steel.
Hot working and cold working of metals – Forging processes – Open, impression and closed die forging – Types of Forging Machines – Typical forging operations. Rolling of metals– Types of Rolling – Flat strip rolling – shape rolling operations – Defects in rolled parts. Principle of rod and wire drawing – Tube drawing – Principles and types of Extrusion – Hot and Cold extrusion.
Mumbai University
Mechanical engineering
SEM III
Material Technology
Module 1.4
Strain Hardening:
Definition importance of strain hardening, Dislocation theory of strain hardening, Effect of strain hardening on engineering behaviour of materials, Recrystallization Annealing: stages of recrystallization annealing and factors affecting it
Steel Hot Rolling, Hot Rolling of Steel, Metal Rolling, Metal Forming Process...Ajjay Kumar Gupta
Steel Hot Rolling, Hot Rolling of Steel, Metal Rolling, Metal Forming Process, Steel Rolling Process, Metalworking, Flat Rolling Fundamentals, Physical Metallurgy, Hot Rolled Steel, Rolling Mills (Pre-Treatment of Hot Metal, Heat Treatments for Hot-Rolled Products, Steelmaking Refractories, Refining of Stainless Steels, Steel Heating for Hot Rolling, Oxygen Steelmaking Processes)
Rolling of steel is one of the most important manufacturing processes for steel. It is usually the first step in the processing of steel after it is made and cast either in Ingot or continuous cast product in a steel melting shop. Hot rolling is used mainly to produce sheet metal or simple cross sections, such as rail tracks.
See more
https://goo.gl/y1STHt
https://goo.gl/S9g5Y4
https://goo.gl/n2H1QS
Contact us:
Niir Project Consultancy Services
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886, 8800733955
Mobile: +91-9811043595
Website :
http://www.niir.org
http://www.entrepreneurindia.co
Tags
Steel Hot Rolling, Hot Rolling of Steel, Metal Rolling, Metal Forming Process, Steel Rolling Process, Metalworking, Flat Rolling Fundamentals, Physical Metallurgy, Hot Rolled Steel, Rolling Mills, Pre-Treatment of Hot Metal, Heat Treatments for Hot-Rolled Products, Steelmaking Refractories, Refining of Stainless Steels, Steel Heating for Hot Rolling, Oxygen Steelmaking Processes, Best small and cottage scale industries, Business guidance for steel rolling industry, Business Plan for a Startup Business, Business plan for steel rolling mill, Business start-up, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot rolling mill process, Hot Rolling Mill, Hot Rolling mill, Hot Strip Mill, How is Steel Produced, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Indian Steel Industry, Industrial steel rolling mill, Modern small and cottage scale industries, Modern steel making technology, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Process & Applications, Process of steelmaking, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Project for startups, Rod and Bar Rolling, Rod and bar rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling process, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Small Start-up Business Project, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel Business, Starting a Steel rolling Business, Starting Steel Mini Mill, Start-up Business Plan for steel rolling, Startup Project for steel rolling business
Processes based on fluidity and solidification, or simply “casting”, include manufacturing techniques whereby molten material is poured or forced into a mould and allowed to harden. Appropriate variants of this technique are particularly suitable for the economical production of complex shapes, ranging from mass-produced parts for the automotive industry to one-of-a-kind production of jewellery or massive machinery.
Concepts of rolling, annealing, quenching, drawing, cold working, hot working...Talha Saleem
pictorial Concepts of rolling, annealing, quenching, drawing, cold working, hot working and forging by simple diagrams.
its just basics. (no explanation )
Characterization and processing of friction stir welding on copper weldseSAT Journals
Abstract FSW(Friction Stir Welding) is a welding technology will be a part of different metals with sensible properties. During this paper, fsw attachment b/n steel, aluminum and copper plates with thicknesses of 3 millimeter was welded. Here we tend to had considered completely different completely different} materials with different combinations i.e copper and copper, copper and aluminum, aluminum & stainless steel, stainless steel & copper. Friction Stir Welding experiments were employed to get the good wieldable properties by maintaining the rpm speeds to 1120 revolutions per minute and attachment speed within the limit of 14-112 mm/min and here we can adjust the pin profile of the location respect to the line butt. Micro struc analysis can be done for examine the parent and the welded material. Cutting and sectioning of the welded pieces for metallographic analysis of the planes which are perpendicular for the attachment and the travelling direction & which is parallel to the friction welding was done. Here the mechanical properties of welding which was were determined by employing the same standard micro hardness and also tensile hardness testing and finding the maximum elongation of the metals to the properties of fsw. From experimental fsw process it can be found the pin profile and also the rotational speed, feed is an important in manufacturing of free welds in fsw of aluminum, copper and steel. Key Words: FSW, Aluminum, copper, stainless steel.
Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing fusion. Welding is distinct from lower temperature techniques such as brazing and soldering, which do not melt the base metal.Welding is a fabrication process whereby two or more parts are fused together by means of heat, pressure or both forming a join as the parts cool. Welding is usually used on metals and thermoplastics but can also be used on wood.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Democratizing Fuzzing at Scale by Abhishek Aryaabh.arya
Presented at NUS: Fuzzing and Software Security Summer School 2024
This keynote talks about the democratization of fuzzing at scale, highlighting the collaboration between open source communities, academia, and industry to advance the field of fuzzing. It delves into the history of fuzzing, the development of scalable fuzzing platforms, and the empowerment of community-driven research. The talk will further discuss recent advancements leveraging AI/ML and offer insights into the future evolution of the fuzzing landscape.
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Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
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Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Courier management system project report.pdfKamal Acharya
It is now-a-days very important for the people to send or receive articles like imported furniture, electronic items, gifts, business goods and the like. People depend vastly on different transport systems which mostly use the manual way of receiving and delivering the articles. There is no way to track the articles till they are received and there is no way to let the customer know what happened in transit, once he booked some articles. In such a situation, we need a system which completely computerizes the cargo activities including time to time tracking of the articles sent. This need is fulfilled by Courier Management System software which is online software for the cargo management people that enables them to receive the goods from a source and send them to a required destination and track their status from time to time.
2. Hot Forming Processes
In hot forming, the work-piece is heated above
its recrystallization temperature thus avoiding
strain hardening.
Types of hot forming processes
• Hot Forging
• Hot Extrusion
• Hot Rolling
3. Different causes of die wear
Causes
Wear
Abrasive
Adhesive
Corrosive
Erosive
Fatigue
Mechanical
Thermal
Catastrophic
Fracture
Extreme Thermal
shock
Extreme
mechanical strains
Poor material
properties
Poor die design
4. Wear Mechanisms
• Abrasive wear: occurs when a hard rough surface slides
across a softer surface. Two modes of abrasive wear are
known as two-body and three-body abrasive wear.
• Corrosive Wear: loss of materials due to the electrochemical
attack.
5. • Adhesive wear: Micro-junctions caused by welding between
the opposing asperities on the rubbing surfaces of the
counter bodies.
• Erosive wear: Impingement of particles (solid, liquid or
gaseous), which remove fragments of materials from the
surface due to momentum effect.
6. HOT FORGING
Main Cause/Factor Effect on Part
Die Wear Out-of-tolerance, inferior appearance
Thermal Fatigue Surface roughening, inferior appearance
Plastic Deformation Out-of-tolerance
Die Breakage Production stoppage
Part Defects Inferior appearance, out-of-tolerance
Effect of main causes on part quality
7. Rank
1
2
3
4
5
6
Factor
Die Wear
Die Breakage (Mechanical
Fatigue)
Plastic Deformation
Thermal Fatigue
Part Defects
Die Breakage (Catastrophic
Failure)
Rank
1
2
3
4
4
4
Factor
Die Breakage
(Catastrophic Failure)
Part Defects
Die Breakage
(Mechanical Fatigue)
Plastic Deformation
Thermal Fatigue
Die Wear
Factors ranked according to frequency Factors ranked according to severity
8. Die Life in Hot forging
• Hot work die steels are used due to their ability to retain their hardness at
elevated temperatures with sufficient strength and toughness to
withstand the stresses that are imposed during forging.
• The property of the die materials can be locally influenced by the surface
engineering techniques such as heat treatments and surface coating
techniques.
• Molybdenum increases resistance to thermal softening, vanadium
improves wear and thermal fatigue characteristics.
• Chromium hot work steels retain their hardness up to 425 °C, tungsten hot
work steels retain their hardness up to 620°C and molybdenum based hot
work steels is in between that of chromium based and tungsten based hot
work die steels.
9. Hot Extrusion
• Extreme temperatures due to heat
transfer between the dies and work
piece.
• The three most commonly reported
modes of die failure are fatigue based
fracture, wear and plastic deformation/
deflection.
10. Failure modes of extrusion dies
• With the large number of sharp corners,
projections and protrusions, slots and
grooves, hollow profiles, fatigue-based
failures (both thermal and mechanical)
the principal failure mode.
• Continually repeated friction between the
extremely hard aluminum-oxide layer on
the billet and the iron-oxide layer at the
bearing surface, and the repeated
renitriding during die maintenance cycles,
wear at the die land should be the likely
second major failure mode.
• The elevated temperatures and pressures
involved, and the necessity of relatively
high extrusion speeds aimed at higher
productivity, plastic deformation and
deflection of critical sections should
closely follow the other two failure
modes.
11. Hot Rolling
• In continuous hot rolling process, billets are processed into rods with
acceptable dimensional tolerance as they pass through the rolling stands,
with the cross sectional shape being progressively altered by the roll
groove.
• The abrasive-wear theory has been generally applied to the die-wear
mechanism in various metals forming process.
Operational factors
• Overloading
• Insufficient stock removal
• Thermal stresses due to insufficient roll
cooling
• Severe bruising of rolls
• Mill chatter, improper crowning and
mechanical alignment problems
• Sharp temperature gradient on the surface
of the rolls (e.g. near strip edge)
• Pickling quality of hot rolled coil
Manufacturer’s factors
• Non metallic inclusions
• Heat treatment faults such as
poor carbide morphology, coarse
martensite, retained austenite
and residual stress
12. Modeling
• Model proposed by Archard is based on the assumption that wear is
proportional to the contact pressure and sliding length of the die material.
This model is presented in the following formula
Where: dV is the wear volume , dp is contact load , dL is the sliding length and H
is tool hardness and k is experimental constant.
dV = k
𝑑𝑝.𝑑𝐿
𝐻
13. Conclusions
• According to Frequency Die wear (Abrasive & Adhesive Mostly) is prominent
factor. Following to this Mechanical Fatigue, Plastic Deformation, Thermal Fatigue,
Part Defects and Catastrophic failure.
• According to severity catastrophic failure is prominent factor. Following to this Part
Defects, Mechanical Fatigue, Plastic Deformation, Thermal Fatigue, Die Wear.
• Factors such as thermal expansion coefficient and thermal conductivity also affect
the die life.
• The dies should also have adequate toughness and fatigue resistance.
• To keep uniform exit cross-sectional area during hot rolling process considering roll
wear, To predict the wear profile of roll for round-oval and oval round passes in hot
rolling process, a modified Archard’s wear model has been proposed.
14. References
• A. F. M. Arif, A. K. Sheikh, S. Z. Qamar, “A Study of die failure mechanisms in aluminum
extrusion”, Journal of Material Processing Technology 134 (2003), 318-328.
• Dong-Hwan Kim, Byung-Min Kim and Youngseog Lee, “Adjustment of Roll Gap for the
Dimension Accuracy of Bar in Hot Bar Rolling Process”, International Journal of the Korean
Society of Precision Engineering, Vol. 4, No. 1, January 2003, 56-62.
• Mayur Deshpande, Dr. Taylan Altan, “Selection of die materials and surface treatments for
increasing die life in hot and warm forging”, The Ohio state University.
• Y. Mae, P. Poonnayom, and A. Wongkrajang, “Wear Mechanism of Hot Forging Die from the
Viewpoint of Diffusion”, Journal of Materials Engineering and Performance, Volume 18(1)
February 2009, 16-20.
• D.H. Kim, H.C. Lee, B.M. Kim, K.H. Kim, “Estimation of die service life against plastic
deformation and wear during hot forging processes”, Journal of Material Processing
Technology 166 (2005), 372-380.