Flashless Forging
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Flashless forging is a closed die forging process where metal is deformed in a die cavity with little to no excess flash. It is conducted at an elevated temperature between cold and hot forging. The preheated workpiece is compressed in the die until deformation occurs, producing a near-net or net-shaped part. Flashless forging requires tight process control of work volume and die cavity size to ensure proper filling. It is well-suited for producing simple, symmetrical parts and precision forgings from materials like aluminum.
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Flashless forging
This document discusses flashless forging, a near net shape forging process where metal is compressed in a die cavity without any excess flash. Flashless forging provides benefits over closed die forging such as material and energy savings from eliminating flash, higher production rates due to no trimming, and better part dimensions and grain structure. While it enables net shape parts and savings, flashless forging also requires more complex dies and strict control over blank weight and temperature compared to conventional forging.
Sheet metal working
This document discusses sheet metal working processes. It begins by explaining that sheet metal forming dates back thousands of years and is used to make a wide variety of consumer and industrial products. The main sheet metal forming processes are stretching, bending, deep drawing, and press working. Press working shapes sheet metal using dies and punches without removing material. The document then goes into details about various sheet metal forming operations, tools, and calculations for processes like bending, deep drawing, blanking, and punching.
Dies Design - Cutting Operations Part 2
Okay, let's calculate the center of pressure step-by-step:
1) Calculate Lx, Ly for each element using the given dimensions
2) Sum Lx = 6.25 + 9.25 + 7 + 5 + 4.25 + 1 = 32.75
3) Sum Ly = 25 + 7.05 + 12.8 + 12.5 + 4.5 + 1.57 = 63.42
4) X (distance from axis YY) = Sum Lx / Sum L = 32.75 / 32.75 = 2.5
5) Y (distance from axis XX) = Sum Ly / Sum L = 63.42 / 32.75 = 1.94
Rod, wire and tube drawing
Rod, wire and tube drawing is a metalworking process where a rod, wire or tube is pulled through a die to reduce its cross-sectional area and increase its length. It involves applying both tensile and compressive forces. Products include wire, rods, and tubes used in applications like electrical wiring, springs and hydraulic tubing. The process offers close dimensional control, lower costs than rolling or extrusion, and can produce very small cross-sections. Lubrication and annealing are important to control work hardening during multiple drawing passes. Dies are commonly made of alloy steels, carbides or diamond to withstand wear from the process.
Forging
Forging is the operation where the metal is heated and then a force is applied to manipulates the metals in such a way that the required final shape is obtained.
Squeeze casting process
Squeeze casting is a near net shape casting process that combines casting and forging to produce parts with high mechanical properties. The process involves pouring liquid metal into a preheated, lubricated die and applying pressure as the metal solidifies. Key parameters that affect the process include casting temperature, die temperature, applied pressure, and pressure duration. A case study examined the effects of varying squeeze pressure, pressure duration, time delay, and die temperature on the density of an LM20 alloy. Squeeze casting produces parts with little to no machining required, low porosity, fine microstructures, and high strength. However, the process also has high costs due to complex tooling and strict control requirements.
Extrusion defects
Irregularities during the process of Extrusion.
These are mainly due to Non uniform flow and stress distribution
U2 p3 core, core prints and chaplets
This document discusses sheet metal operations and core manufacturing in casting. It defines cores as models of interior surfaces that are inserted into molds. Cores require supports like chaplets to hold them in position. The document outlines core parts, types, characteristics, functions and manufacturing. Cores are made of sand or metal and can be horizontal, vertical, balanced or hanging depending on their shape and position in molds. Core boxes are used to form cores and come in types like half, split, dump and loose piece. Core prints secure cores and must withstand forces from the molten metal. The document provides equations and guidelines for proper core print sizing.
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Flashless forging
This document discusses flashless forging, a near net shape forging process where metal is compressed in a die cavity without any excess flash. Flashless forging provides benefits over closed die forging such as material and energy savings from eliminating flash, higher production rates due to no trimming, and better part dimensions and grain structure. While it enables net shape parts and savings, flashless forging also requires more complex dies and strict control over blank weight and temperature compared to conventional forging.
Sheet metal working
This document discusses sheet metal working processes. It begins by explaining that sheet metal forming dates back thousands of years and is used to make a wide variety of consumer and industrial products. The main sheet metal forming processes are stretching, bending, deep drawing, and press working. Press working shapes sheet metal using dies and punches without removing material. The document then goes into details about various sheet metal forming operations, tools, and calculations for processes like bending, deep drawing, blanking, and punching.
Dies Design - Cutting Operations Part 2
Okay, let's calculate the center of pressure step-by-step:
1) Calculate Lx, Ly for each element using the given dimensions
2) Sum Lx = 6.25 + 9.25 + 7 + 5 + 4.25 + 1 = 32.75
3) Sum Ly = 25 + 7.05 + 12.8 + 12.5 + 4.5 + 1.57 = 63.42
4) X (distance from axis YY) = Sum Lx / Sum L = 32.75 / 32.75 = 2.5
5) Y (distance from axis XX) = Sum Ly / Sum L = 63.42 / 32.75 = 1.94
Rod, wire and tube drawing
Rod, wire and tube drawing is a metalworking process where a rod, wire or tube is pulled through a die to reduce its cross-sectional area and increase its length. It involves applying both tensile and compressive forces. Products include wire, rods, and tubes used in applications like electrical wiring, springs and hydraulic tubing. The process offers close dimensional control, lower costs than rolling or extrusion, and can produce very small cross-sections. Lubrication and annealing are important to control work hardening during multiple drawing passes. Dies are commonly made of alloy steels, carbides or diamond to withstand wear from the process.
Forging
Forging is the operation where the metal is heated and then a force is applied to manipulates the metals in such a way that the required final shape is obtained.
Squeeze casting process
Squeeze casting is a near net shape casting process that combines casting and forging to produce parts with high mechanical properties. The process involves pouring liquid metal into a preheated, lubricated die and applying pressure as the metal solidifies. Key parameters that affect the process include casting temperature, die temperature, applied pressure, and pressure duration. A case study examined the effects of varying squeeze pressure, pressure duration, time delay, and die temperature on the density of an LM20 alloy. Squeeze casting produces parts with little to no machining required, low porosity, fine microstructures, and high strength. However, the process also has high costs due to complex tooling and strict control requirements.
Extrusion defects
Irregularities during the process of Extrusion.
These are mainly due to Non uniform flow and stress distribution
U2 p3 core, core prints and chaplets
This document discusses sheet metal operations and core manufacturing in casting. It defines cores as models of interior surfaces that are inserted into molds. Cores require supports like chaplets to hold them in position. The document outlines core parts, types, characteristics, functions and manufacturing. Cores are made of sand or metal and can be horizontal, vertical, balanced or hanging depending on their shape and position in molds. Core boxes are used to form cores and come in types like half, split, dump and loose piece. Core prints secure cores and must withstand forces from the molten metal. The document provides equations and guidelines for proper core print sizing.
Metal casting Process
Sand Casting : Sand Mould – Type of patterns - Pattern Materials – Pattern allowances –Moulding sand Properties and testing – Cores –Types and applications – Moulding machines– Types and applications; Melting furnaces : Blast and Cupola Furnaces; Principle of special casting processes : Shell - investment – Ceramic mould – Pressure die casting - Centrifugal Casting - CO2 process – Stir casting; Defects in Sand casting.
Deep drawing
Deep drawing is a metal forming process where a flat sheet is formed into a hollow shape using a punch and die. The sheet is placed over the die opening and held in place by a blank holder. The punch then forces the sheet into the die cavity, forming it into the desired shape. Deep drawing can produce complex 3D shapes from sheet metal and offers advantages like high production rates and consistency. However, defects may occur like tearing, wrinkling, thinning, or earing if the process is not controlled properly.
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Stretch forming
Stretch forming is a sheet metal forming process where a sheet blank is clamped at the edges and formed using a rigid punch. There are several types of stretch forming including simple, tangential, Cyril-Bath, and multi-sided stretch forming. Tangential stretch forming applies a tensile stress before forming for more uniform deformation. The Cyril-Bath process uses grips that move horizontally and vertically to form parts in a press. Multi-sided stretch forming clamps the blank on all sides for complex geometries. Stretch forming is used to produce large, flat parts with low tooling costs.
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This document discusses various sheet metal forming processes. It describes cutting processes like shearing, blanking, and punching. It also describes bending, drawing, embossing, stretch forming, roll forming, and spinning. Sheet metal is commonly used to make parts for vehicles, appliances, furniture and more. Cutting is done using punches and dies in presses or shears. Proper clearance and tool sizes are important. Bending involves straining metal around an axis. Drawing forms complex curved shapes using punches and dies.
Advanced casting and welding
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INTRODUCTION TO MOULDING , LECTURE NOTES ANKIT SAXENA Asst. Prof. @ Dr. Akhilesh Das Gupta Institute of Technology and Management, New Delhi
Production Technology Lecture Notes as per GGSIPU SYLLABUS FOR UNIT 1.
Casting is a process in which molten metal is allowed to solidify in a predefined mould cavity. After the solidification by breaking the mould the component is taken out. This is known as CASTING.
Pattern is a replica of a object to be made with some modifications.
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Types of Patterns
Pattern Design Considerations
Pattern Allowances
Pattern Making
Pattern Layout
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Sheet Metal Forming
1. Sheet metal forming operations include bending, stretching, deep drawing, and other processes where sheets are formed. Bending involves shaping a straight length into a curve and can be done using presses or rolls.
2. Deep drawing uses a die and punch to shape flat sheets into cup-shaped parts. Stretch forming clamps sheet edges and stretches the sheet over a die into the desired shape.
3. Successful forming requires considering the material properties, die and process parameters to avoid defects like cracks, wrinkles, and non-uniform thinning. Minimum bend radii, lubrication, and holding pressure all impact the quality of formed parts.
Sheet Metal Forming
This document provides information on various sheet metal forming processes. It discusses the characteristics of sheet metal and tests used to determine formability. The main sheet metal forming processes covered are tube bending and forming as well as bending of sheet and plate. Tube bending can be done via press bending, rotary drawing, heat induction, roll bending, and sand packing. Sheet and plate bending includes techniques like roll bending, air bending, bottoming, coining, folding, wiping, and rotary bending. Common applications of sheet metal forming in industries like automotive, aircraft, appliances, and furniture are also mentioned.
Cold isostatic pressing
Cold isostatic pressing (CIP) is a technique where high pressure is applied uniformly to metal powder sealed in a flexible container. This compacts the powder to a density of 75-85% without die wall friction, resulting in a part with uniform density and no residual stresses. There are two methods - the wet bag process suited for batch production of complex parts, and the dry bag process using a fixed mold for mass production. CIP is used to make intricate or long shapes out of materials like titanium, tool steels, tungsten, and molybdenum powders.
FORGING
Forging is a metalworking process where a metal workpiece is shaped by applying compressive forces. It can produce parts that are stronger than those made by other metalworking processes. There are two main types of forging: open die forging between flat dies for larger objects, and closed die forging between shaped dies for smaller, more precise components. Common metals forged include carbon steels, aluminum, and titanium. The forging process involves heating metal, shaping it between dies using presses, trimming off excess flash, and often further processing like heat treating. Forgings are found in critical applications like engines and chassis where strength and reliability are important.
Press work
Press working is a manufacturing process that uses presses to form sheet metal components. It involves both cutting and non-cutting operations. Common cutting operations include blanking, punching, trimming, and notching. Common non-cutting operations include bending, drawing, and squeezing. A press machine consists of a bed, bolster plate, die set with lower and upper shoes, punches, and other components. The travel of the punch during penetration progresses through three zones: compression, shearing, and breakage. Clearance is applied between the punch and die depending on whether the operation is punching or blanking. Different types of die sets are used depending on the shape and complexity of the part being formed.
press operation
This document provides an overview of press working and various sheet metal forming operations. It defines press working as a chipless manufacturing process that uses a press machine to form sheet metal components by applying force. It then describes common sheet metal cutting operations like blanking, punching, trimming, shaving, notching, and shearing. Forming operations like bending and embossing are also summarized. The document aims to introduce students to basic press tool operations for modifying sheet metal geometry.
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This document discusses permanent mold casting. Permanent mold casting uses metal molds that are repeatedly used to produce many castings of the same form. The liquid metal enters the mold by gravity. It is used for high volume production of small, simple parts made of non-ferrous metals like aluminum alloys. Common applications include gears, housings, and automotive and aircraft parts. The process yields castings with good mechanical properties, dimensional tolerances, surface finishes, and production rates. However, it requires expensive tooling for low volumes and some part shapes cannot be molded.
Casting
The document discusses the process of sand casting. It begins by defining foundry and casting as the process of producing metal parts by pouring molten metal into a prepared mold. It then provides terminology used in casting such as flask, pattern, parting line, pouring basin, sprue, runner, riser, gate, core, and chaplets. The steps of sand casting are outlined as making the pattern, preparing sand mixtures, making the mold and cores, melting metal, pouring, cleaning, inspecting, and heat treating. Common casting materials and applications are also listed.
Casting and types
This document discusses various casting processes including investment casting, plaster mold casting, ceramic mold casting, permanent mold casting, and die casting. It describes the key steps in each process and notes advantages and limitations. Defects that can occur in castings such as misruns, cold shuts, and shrinkage cavities are also outlined.
Forming process forging
The document discusses two main forging processes: open die forging and closed die forging. Open die forging uses simple flat dies and is used for large or low volume parts. Closed die forging uses carefully machined matching dies to produce parts to close tolerances. The process involves preforming billets, rough forging in blocking dies, finishing in final dies, and trimming flash. Closed die forging produces parts with good dimensions and properties but requires high die costs for small volumes.
Forging Process. [Workshop Practices]
Forging is an ancient metalworking process where a metal is compressed under force into a desired shape. It can be done using a hammer and anvil and produces parts with good strength and toughness. There are different types of forging processes, including open-die forging using flat dies, impression-die forging where the workpiece takes the shape of shaped die cavities, and coining where parts are precisely forged without lubricants between dies. Forged parts often require additional heat treating for optimal properties.
Forging processes
Smith forging, also called flat die or open die forging, uses simple flat-faced dies and stock tooling to produce workpieces with less accuracy than impression or closed die forging. Impression die forging uses cavities in specially prepared dies to produce forged shapes in large quantities through drop, press, or machine forging. Closed die forging places a heated workpiece on a lower die while an upper die forces the metal to fill die contours. Hand forging shapes small forgings through hammering heated metal on anvils while power hammers and presses are used to forge larger parts through blows or squeezing.
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Deep drawing is a metal forming process where a flat sheet is formed into a hollow shape using a punch and die. The sheet is placed over the die opening and held in place by a blank holder. The punch then forces the sheet into the die cavity, forming it into the desired shape. Deep drawing can produce complex 3D shapes from sheet metal and offers advantages like high production rates and consistency. However, defects may occur like tearing, wrinkling, thinning, or earing if the process is not controlled properly.
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Sheet metal operations are cold-working processes that can manufacture low-cost metal parts in high volumes quickly. Sheet metal is metal between 0.006-0.25 inches thick that can be cut, bent, or stretched into various shapes. Common sheet metal operations include embossing to add raised or sunken designs using heat and pressure, coining to add similar impressions to both sides, spinning to shape metal over a rotating mandrel, stretch forming to simultaneously stretch and bend metal over a die, and nibbling which cuts contoured shapes using overlapping slits.
Stretch forming
Stretch forming is a sheet metal forming process where a sheet blank is clamped at the edges and formed using a rigid punch. There are several types of stretch forming including simple, tangential, Cyril-Bath, and multi-sided stretch forming. Tangential stretch forming applies a tensile stress before forming for more uniform deformation. The Cyril-Bath process uses grips that move horizontally and vertically to form parts in a press. Multi-sided stretch forming clamps the blank on all sides for complex geometries. Stretch forming is used to produce large, flat parts with low tooling costs.
Sheet metal working
This document discusses various sheet metal forming processes. It describes cutting processes like shearing, blanking, and punching. It also describes bending, drawing, embossing, stretch forming, roll forming, and spinning. Sheet metal is commonly used to make parts for vehicles, appliances, furniture and more. Cutting is done using punches and dies in presses or shears. Proper clearance and tool sizes are important. Bending involves straining metal around an axis. Drawing forms complex curved shapes using punches and dies.
Advanced casting and welding
Casting is a manufacturing process where liquid material is poured into a mold and allowed to solidify. The solidified part is known as a casting. Investment casting, also known as lost-wax casting, involves creating a wax pattern, coating it with refractory material to create a ceramic mold, melting away the wax to leave a cavity, and pouring molten metal into the mold cavity. This allows for very intricate parts to be cast with close tolerances and smooth finishes. Investment casting is commonly used for parts that are difficult to machine from difficult to machine alloys like aluminum, copper, and steels.
INTRODUCTION TO MOULDING , LECTURE NOTES
INTRODUCTION TO MOULDING , LECTURE NOTES ANKIT SAXENA Asst. Prof. @ Dr. Akhilesh Das Gupta Institute of Technology and Management, New Delhi
Production Technology Lecture Notes as per GGSIPU SYLLABUS FOR UNIT 1.
Casting is a process in which molten metal is allowed to solidify in a predefined mould cavity. After the solidification by breaking the mould the component is taken out. This is known as CASTING.
Pattern is a replica of a object to be made with some modifications.
Pattern Materials
Difference between Pattern and Casting
Types of Patterns
Pattern Design Considerations
Pattern Allowances
Pattern Making
Pattern Layout
Properties of moulding sand
Testing of Moulding Sand
Special casting processComponents of die
The document discusses the main components of a die, which is a tool used in manufacturing to cut or shape materials. It describes the basic components as die plates, shoes, and sets which form the foundation. Other components include guide pins and bushings for alignment, heel blocks and plates to absorb side thrust, screws, dowels, and keys for fastening. Pads are used for holding, controlling, or stripping metal. Spools, shoulder bolts, and keepers fasten pads while allowing movement. Retainers secure cutting and forming components, and springs provide the necessary force.
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Sheet Metal Forming
1. Sheet metal forming operations include bending, stretching, deep drawing, and other processes where sheets are formed. Bending involves shaping a straight length into a curve and can be done using presses or rolls.
2. Deep drawing uses a die and punch to shape flat sheets into cup-shaped parts. Stretch forming clamps sheet edges and stretches the sheet over a die into the desired shape.
3. Successful forming requires considering the material properties, die and process parameters to avoid defects like cracks, wrinkles, and non-uniform thinning. Minimum bend radii, lubrication, and holding pressure all impact the quality of formed parts.
Sheet Metal Forming
This document provides information on various sheet metal forming processes. It discusses the characteristics of sheet metal and tests used to determine formability. The main sheet metal forming processes covered are tube bending and forming as well as bending of sheet and plate. Tube bending can be done via press bending, rotary drawing, heat induction, roll bending, and sand packing. Sheet and plate bending includes techniques like roll bending, air bending, bottoming, coining, folding, wiping, and rotary bending. Common applications of sheet metal forming in industries like automotive, aircraft, appliances, and furniture are also mentioned.
Cold isostatic pressing
Cold isostatic pressing (CIP) is a technique where high pressure is applied uniformly to metal powder sealed in a flexible container. This compacts the powder to a density of 75-85% without die wall friction, resulting in a part with uniform density and no residual stresses. There are two methods - the wet bag process suited for batch production of complex parts, and the dry bag process using a fixed mold for mass production. CIP is used to make intricate or long shapes out of materials like titanium, tool steels, tungsten, and molybdenum powders.
FORGING
Forging is a metalworking process where a metal workpiece is shaped by applying compressive forces. It can produce parts that are stronger than those made by other metalworking processes. There are two main types of forging: open die forging between flat dies for larger objects, and closed die forging between shaped dies for smaller, more precise components. Common metals forged include carbon steels, aluminum, and titanium. The forging process involves heating metal, shaping it between dies using presses, trimming off excess flash, and often further processing like heat treating. Forgings are found in critical applications like engines and chassis where strength and reliability are important.
Press work
Press working is a manufacturing process that uses presses to form sheet metal components. It involves both cutting and non-cutting operations. Common cutting operations include blanking, punching, trimming, and notching. Common non-cutting operations include bending, drawing, and squeezing. A press machine consists of a bed, bolster plate, die set with lower and upper shoes, punches, and other components. The travel of the punch during penetration progresses through three zones: compression, shearing, and breakage. Clearance is applied between the punch and die depending on whether the operation is punching or blanking. Different types of die sets are used depending on the shape and complexity of the part being formed.
press operation
This document provides an overview of press working and various sheet metal forming operations. It defines press working as a chipless manufacturing process that uses a press machine to form sheet metal components by applying force. It then describes common sheet metal cutting operations like blanking, punching, trimming, shaving, notching, and shearing. Forming operations like bending and embossing are also summarized. The document aims to introduce students to basic press tool operations for modifying sheet metal geometry.
Permanent mold casting
This document discusses permanent mold casting. Permanent mold casting uses metal molds that are repeatedly used to produce many castings of the same form. The liquid metal enters the mold by gravity. It is used for high volume production of small, simple parts made of non-ferrous metals like aluminum alloys. Common applications include gears, housings, and automotive and aircraft parts. The process yields castings with good mechanical properties, dimensional tolerances, surface finishes, and production rates. However, it requires expensive tooling for low volumes and some part shapes cannot be molded.
Casting
The document discusses the process of sand casting. It begins by defining foundry and casting as the process of producing metal parts by pouring molten metal into a prepared mold. It then provides terminology used in casting such as flask, pattern, parting line, pouring basin, sprue, runner, riser, gate, core, and chaplets. The steps of sand casting are outlined as making the pattern, preparing sand mixtures, making the mold and cores, melting metal, pouring, cleaning, inspecting, and heat treating. Common casting materials and applications are also listed.
Casting and types
This document discusses various casting processes including investment casting, plaster mold casting, ceramic mold casting, permanent mold casting, and die casting. It describes the key steps in each process and notes advantages and limitations. Defects that can occur in castings such as misruns, cold shuts, and shrinkage cavities are also outlined.
Forming process forging
The document discusses two main forging processes: open die forging and closed die forging. Open die forging uses simple flat dies and is used for large or low volume parts. Closed die forging uses carefully machined matching dies to produce parts to close tolerances. The process involves preforming billets, rough forging in blocking dies, finishing in final dies, and trimming flash. Closed die forging produces parts with good dimensions and properties but requires high die costs for small volumes.
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Forging is an ancient metalworking process where a metal is compressed under force into a desired shape. It can be done using a hammer and anvil and produces parts with good strength and toughness. There are different types of forging processes, including open-die forging using flat dies, impression-die forging where the workpiece takes the shape of shaped die cavities, and coining where parts are precisely forged without lubricants between dies. Forged parts often require additional heat treating for optimal properties.
Forging processes
Smith forging, also called flat die or open die forging, uses simple flat-faced dies and stock tooling to produce workpieces with less accuracy than impression or closed die forging. Impression die forging uses cavities in specially prepared dies to produce forged shapes in large quantities through drop, press, or machine forging. Closed die forging places a heated workpiece on a lower die while an upper die forces the metal to fill die contours. Hand forging shapes small forgings through hammering heated metal on anvils while power hammers and presses are used to forge larger parts through blows or squeezing.
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Topic 4 metal forming 160214
The document discusses metal forming processes. It describes bulk deformation processes like rolling, forging, extrusion, and wire/bar drawing which use plastic deformation to change the shape of metal workpieces. These processes apply stresses that exceed the metal's yield strength. The document outlines factors that influence metal forming like material properties, temperature, friction, and lubrication. It provides an overview of different forming techniques and their characteristics.
Ch14 forging Erdi Karaçal Mechanical Engineer University of Gaziantep
The document discusses the process of forging metals. It describes how forging involves shaping metals using dies or molds by applying compressive forces. It can produce complex shapes and achieve a dense grain structure. Forging is often used to make components that require high strength, such as landing gear or connecting rods. The document outlines various forging techniques including impression die forging, cogging, upsetting, and swaging and discusses how they influence the microstructure and properties of forged parts.
Sheet metal Forming Process
Sheet metal stamping was developed in the 1890s for mass production of bicycles, playing an important role in making interchangeable parts economical. Basic sheet forming processes include shearing, bending, drawing, and involve tools like shear presses, brake presses, and finger presses. Material selection is critical, balancing formability with strength, weight, cost, and corrosion resistance. Stretch forming allows tighter tolerances than stamping but is difficult for complex shapes. New developments include tailored blanks, binder force control, and quick die exchange. Alternative auto body materials offer cost and environmental benefits compared to steel.
Semi Solid Metal Casting
Semi-solid metal casting (SSM) involves processing metals between their liquidus and solidus temperatures, when they are partially solidified. This allows for modifying the dendritic microstructure and improving mechanical properties compared to fully liquid casting. SSM techniques include thixocasting, which uses pre-cast semi-solid billets that are reheated and injected into dies, and rheocasting, where the liquid metal is sheared as it cools through the semi-solid range. SSM offers advantages over traditional casting like reduced porosity and finer microstructures, making it suitable for high-strength automotive and machine components.
Laser ignition system
This document summarizes a seminar presentation on laser ignition systems for internal combustion engines. It begins with an introduction explaining the need to reduce environmental impacts while continuing to use IC engines. It then describes how lasers work and the types of lasers that exist. The rest of the document discusses laser ignition in more detail, including the components, how it works compared to conventional spark plug ignition, the advantages it provides like improved lean burning and flexible ignition locations, and experiments conducted using ND:YAG lasers.
Mechanical working of metals
This document discusses various mechanical working processes for metals, including hot working, cold working, and recrystallization temperature. It describes processes such as forging, extrusion, drawing, rolling, and sheet metal forming. Forging methods like open die forging, press forging, upset forging, and closed die forging are explained. The advantages and uses of hot forging and cold forging are summarized. Extrusion, drawing, and common applications are also outlined briefly.
PPT ON FORGING
This document discusses various types of forging processes including hot forging, press forging, swaging, and cold forging. It describes how each process uses compressive forces and dies to shape metal at different temperatures. Examples of specific forging techniques are provided like hammer forging, drop forging, and upset forging. The document also outlines common forging tools, defects that may occur, and applications in small tools and automotive manufacturing.
Metal spinning Process
The document provides an overview of the metal spinning process. It discusses the history and classification of different metal spinning techniques. The basic metal spinning process involves clamping a metal blank between a spinning mandrel and follower, and using specially designed tools to form the blank into an axially symmetric product while it rotates at high speeds. Key aspects covered include the mechanics of cone spinning, use of multi-pass spinning for small cone angles, mandrel and tool design, lubricants, common spinning machines, advantages over other forming processes, and applications.
Forging
Forging processes involve shaping metals by applying compressive forces. There are four main types: hammer/drop forging uses gravity impacts, press forging uses hydraulic or mechanical presses, and open-die and closed-die forging differ in whether dies fully contain the metal. Forging increases strength by working the metal and altering its microstructure. Proper die and process design are needed to control metal flow, fill dies completely, and minimize flash and defects. Die materials must withstand thermal and mechanical stresses, while coatings can extend die life.
Ch19
The document discusses various bulk metal forming processes including rolling, forging, extrusion, and wire/bar drawing. It provides details on:
- Rolling processes like flat rolling and shape rolling and the equipment used.
- Forging processes like open-die, impression-die, and flashless forging. Products include crankshafts and gears.
- Extrusion processes like direct and indirect extrusion which produce long, uniform cross-section parts.
- Wire and bar drawing which reduces cross-section by pulling metal through a die, similar to extrusion.
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Ch14 forging Erdi Karaçal Mechanical Engineer University of Gaziantep
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F O R G I N G & E X T R U S I O N
This document discusses various bulk deformation processes including forging and extrusion. It describes different forging techniques like open-die, closed-die, and impression-die forging. Extrusion involves forcing a heated billet through a die to produce a part. Key factors that affect forging and extrusion are discussed, such as die design, temperature, speed, and the extrusion ratio. Common defects and parts produced via these processes are also mentioned.
Metal forming processes full
Metal forming processes involve plastic deformation of materials to shape them. The main bulk metal forming processes are forging, extrusion, and rolling. Forging involves compressing material between dies to impart the die shape. Extrusion uses a ram to force material through a die opening to shape its cross-section. Rolling reduces thickness by compressing material between rotating rolls.
Chapter-14-forging11.pptx
This document provides an overview of forging processes and techniques. It discusses various forging operations like open die forging, impression die forging, and closed die forging. It also describes defects that can occur during forging and considerations for die design, materials, and lubrication. Key factors that influence forgeability of metals are also summarized.
3604198 (2).ppt
This document provides an overview of forging processes and operations. It describes various forging techniques including open die forging, impression die forging, closed die forging, precision forging, coining, heading, piercing, hubbing, orbital forging, and isothermal forging. Equations for calculating forging forces are provided. Examples of typical forged products like bolts, gears, and hand tools are given. Diagrams illustrate the different steps in various forging processes.
Extrusion, Drawing, Forging and Sheetmetal working processes
This Material presents about metal forming processes from those it slides about bulk deformation and sheet metal working processes includes (extrusion, drawing, forging and sheet metal operations).
Kalp Chap 15 Extrusion and Drawing.ppt
This document discusses extrusion and drawing manufacturing processes. Extrusion involves forcing a billet through a die to reduce its cross-section into a constant shape. Drawing reduces the cross-section of a round rod or wire by pulling it through a die. Both processes involve controlling variables like temperature, speed, lubrication, and die design to shape the material and minimize defects from stresses, cracking, or non-uniform flow.
presentation1-171103141859_removed_removed.pptx
Orbital forging is a continuous forging process where one die rotates relative to the other, gradually deforming a small area of the workpiece at a time until final shape is achieved. The tilt angle between dies determines the forging force applied, with larger tilt angles requiring smaller forces but making machine design and maintenance more difficult. Orbital forging allows production of symmetric and some asymmetric parts, has lower forces and costs than other forging methods, and can produce net-shape parts in shorter cycle times. However, it is limited to certain part geometries and requires trial and error to determine suitability.
mod 6.pptx
Rolling is a metal forming process where metal stock is passed through one or more pairs of rolls to reduce the thickness and increase the length. There are different types of rolling mills such as two-high mill, three-high mill, four-high mill, cluster mill, and tandem mill. Hot rolling is carried out above the recrystallization temperature of the metal to aid plastic deformation while cold rolling is done below the recrystallization temperature. Extrusion is a process where a round billet is forced through a die opening by a ram to produce a continuous profile. Common extruded parts include window frames and tubing.
Metal forming(foriging)
Forming operations are those in which the shape of a metal piece is changed by plastic deformation; for example, forging, rolling, extrusion, and drawing are common forming techniques.
Metal forming(foriging)
Forging is a deformation process in which the work part is compressed between two dies, using either impact or gradual pressure to form the part.
Forging
The document discusses various metal forming processes including forging processes like open die, closed die, and impression forging. It describes types of rolling processes and defects in rolled parts. It also covers principles of extrusion, types of extrusion, and tube drawing. Different metal forming techniques like forging, rolling, and extrusion are discussed along with their advantages in shaping metals and improving mechanical properties. Key terms related to forging like dies, forgings, and defects in forged parts are also summarized.
Forging final
Forging: open and closed die forging, forging operations, hammer forging, press forging and drop forging, forging defects, their causes and remedies.
Forging ppt
Forging is a metalworking process that uses compressive forces to shape materials by plastic deformation. It is carried out either hot or cold. The material is heated and shaped by hammer blows or presses. It produces stronger parts than casting or machining due to improved grain structure and lack of defects. Common forging applications include bolts, gears, crankshafts, and connecting rods. Forging can be classified by loading type, operating temperature, or die arrangement and involves steps like heating, shaping, heat treatment, and inspection.
Bulk deformation unit 3 notes
This document discusses various bulk deformation techniques including forging, rolling, and extrusion. It covers topics like hot working versus cold working, the advantages of each, and specific forging processes like closed-die forging. Forging refines grain structure and improves properties. It describes how grain flow follows the deformation pattern. The document also discusses forging equipment, defects, and provides examples of forging a connecting rod and crankshaft.
Forging and-press-working-8248098
This document provides an overview of forging and press working processes. It defines forging as plastically deforming metal at elevated temperatures using compressive forces. The document classifies forging methods as open die, closed die, drop, hammer, and press forging based on the process and equipment used. It also defines press working and classifies press types and operations including cutting operations like blanking and punching, and forming operations like bending and drawing. Key tools for forging like hammers, tongs, and dies are also introduced.
Forging & Press Working
This document provides an overview of forging and press working processes. It defines forging as plastically deforming metal under compressive force at elevated temperatures using tools like hammers or presses. Forging is classified as open die or closed die based on the tools used, and as hammer, press, drop or machine forging based on the equipment. Press working involves shaping sheet metal between dies in a press machine. Common press working operations include cutting via blanking, punching and forming through bending and drawing.
Honing and Laping machines
This document provides an overview of honing and lapping machines used for microfinishing processes. It defines honing as a grinding process that uses bonded abrasive stones called hones to finish round holes. Key details about honing include that it is used to correct out-of-roundness, taper, tool marks, and other hole geometry issues. It also discusses honing tools, machines, advantages, and disadvantages. Lapping is defined as an abrasive process that uses loose abrasives between a lap and workpiece with relative motion to achieve precision finishing. Details about lap materials, abrasives, speeds, and methods such as hand and machine lapping are provided.
MP-II-UNIT 7 JSS_BROACHING.pptx
The document discusses broaching and finishing processes. Broaching is described as a machining process that can produce high surface finish, accuracy and is suitable for mass production. Horizontal, vertical and continuous broaching machines are discussed. Finishing processes like lapping and honing are then covered. Lapping involves abrasive particles to produce extreme dimensional accuracy. Honing uses an abrasive stone that rotates and strokes to produce round, crosshatched bores with good surface finish. Advantages and limitations of broaching, lapping and honing are provided.
Sheet metal processes
The document provides information on various sheet metal processes including sheet metal basics, classifications, cutting, bending, deep drawing, ironing, spinning, hydroforming, and explosive forming. It discusses the mechanics and considerations for processes like cutting, bending, deep drawing, and defines related terms like clearance, drawing ratio, reduction, etc. The document is intended to educate readers on fundamental sheet metal engineering concepts and manufacturing techniques.
Forging process
The document discusses various metal forming techniques including open-die forging, impression-die forging, and flashless forging. It describes how each process works and provides examples of parts made using forging. Defects that can occur during forging like unfilled sections, cold shuts, and scale pits are also reviewed. Different types of forging machines like drop hammers and presses are introduced.
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Extrusion, Drawing, Forging and Sheetmetal working processes
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Industrial psychology is the study of human behavior in work environments and how to minimize problems. It aims to increase productivity while maintaining human values like health and satisfaction. Technological advances have automated many jobs. Industrial psychologists were initially concerned with selection but now address various areas like training, safety, and morale. Research identifies problems like turnover and conflict then applies findings to solve issues. Measurement scales are used to characterize job-related behaviors influencing productivity. Basic research strategies start by identifying variables to study and appropriate treatment and settings.
Deformation
Deformation is a change in the shape or size of an object due to an applied force or temperature change. There are two types of mechanical work where material undergoes plastic deformation: hot working, which is performed above the material's recrystallization temperature, and cold working, which is performed below the recrystallization temperature. Hot working has advantages over cold working as it requires less energy and improves material properties through grain refinement. Common hot working processes include rolling, forging, extrusion, and drawing.
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The document discusses the dimensions of engineering ethics. It notes that engineering ethics are important for reasons beyond avoiding legal trouble and ensuring safety, but also for the survival of the profession itself. Engineering codes of ethics have been established by professional societies and are emphasized in engineering curricula. Ethics provide the framework for addressing evolving issues related to the engineering profession. The document then explores the different senses and meanings of the term "engineering ethics," including that ethics describe a set of beliefs, attitudes, and habits related to engineering.
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The document discusses engineering ethics, which is defined as the study of moral issues and decisions confronting individuals and organizations engaged in engineering. It notes that engineering ethics examines the moral principles, values, and acceptable behaviors in engineering practice and research. The document also outlines various aspects of engineering ethics including moral values, responsibilities, dilemmas, technological development, and the scope of issues at both the micro and macro levels.
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This document discusses the rights of engineers as humans, employees, and professionals. It outlines three key professional rights: (1) the right of professional conscience to exercise technical and moral judgment; (2) the right of conscientious refusal to avoid unethical behavior; and (3) the right to professional recognition including fair pay and credit. The document also examines employees' rights to privacy, nondiscrimination, and whistleblowing, defining the latter as conveying information about moral problems through unofficial channels.
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Engineers have a responsibility to protect public safety, health and welfare above all other concerns. Their codes of ethics require technical competence and continuing education, and forbid conflicts of interest. Most professions have codes of conduct to prevent client exploitation and maintain integrity, benefitting both clients and members. Principles of engineering ethics include prioritizing public safety, only practicing within one's expertise, issuing truthful public statements, and avoiding unfair competition or corruption.
Manual straightening
Heat straightening is a repair method for damaged steel that uses controlled heat application and cooling cycles to gradually straighten the material without using external force. It involves heating only the deformed regions of the steel to below its lower critical temperature and yield stress point, then allowing it to cool slowly. This causes the steel to straighten over multiple heating cycles. Hot mechanical straightening and hot working are different in that they use external forces above the steel's yield stress during or after heating, which can damage the steel and reduce its strength. Heat straightening is a predictable method that avoids these risks.
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Drop forging is a manufacturing process that shapes metals by hammering or pressing them between two dies. There are two main types - open die forging, where the operator positions the workpiece for each press, and closed die forging, where both upper and lower dies form the part in a single press. Closed die forging produces near-net shapes and is best for high production runs, while open die is used for simpler parts or prototype work. Common applications include tools, gears, and vehicle components.
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Flashless Forging
- 1. Flashless Forging Lalaguna, Rachel C.
- 2. Flashless Forging • "true" closed die forging in which metal deformed in a die cavity permits virtually no excess metal to escape. • Carried out in an elevated temperature which in between cold and hot forging. • Warmed work piece is compressed between a punch and a die having the shape of the compressor scroll or balance plate until deformation occurs.
- 3. flashless forging imposes requirements on process control that are more demanding than impression die forging . most important is that the work volume must equal the space in the die cavity within. Very close tolerance if the starting blank is too large excessive pressures may cause damage to the die or press. if the blank is too small, the cavity will not be filled because of the special demands by flashless forging . the process lends itself best to part geometrics that are usually simple and symmetrical and to work materials such as a precision forging process.
- 4. application
- 5. • . The process is used to produce a near-net or net shape forging. The dies make no provision for flash because the process does not depend on the formation of flash to achieve complete filling. Actually, a thin fin or ring of flash may form in the clearance between the upper punch and die, but it is easily removed by blasting or tumbling operations, and does not require a trim die. The process is therefore called "flashless forging", and is sometimes called "enclosed die forging".
- 6. Application
- 7. Advantages of flashless forging • Part produced is more ductile. • Higher strength. • Higher production rate. • Little or no material is wasted. • Produced part are in net shape.
- 8. disadvantage • Higher tooling cost due to complex die shape.
- 9. With flash Flashless
- 10. figure 19.17 flashless forging (1)just before initial contact with work piece, (2)partial compression, and (3)final punch and die closure. Symbols v and f indicate motion(v=velocity) and applied force respectively • coining is of course in the minting of coins shown in Figure 19.18. The process is also used to provide good surface finish and dimensional accuracy on workparts made by other operation.
- 11. FIGURE 19.18 Coining operation (1) Start of cycle(2) Compression Stroke (3) Ejection of Finish part
- 12. Application
- 13. Thank you!