This document provides information on various forging processes and equipment. It discusses open die forging, impression forging, precision forging, and defines standard forging terminology. It describes various forging operations like upsetting, edging, fullering, drawing, swaging, piercing, punching, bending, roll forging, and skew rolling. It also discusses cogging, forging between dies, precision forging, die inserts, swaging, rotary swaging, tube swaging, and coining. The document outlines different types of forging machines like hammers, presses, screw presses and their characteristics. It concludes by listing common forging defects.
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.
Extrusion is a process where a block of metal is reduced in cross-section by forcing it to flow through a die under high pressure. There are different types of extrusion classified by direction (direct/indirect), temperature (hot/cold), and equipment (horizontal/vertical presses). Key equipment includes presses, dies, and tools. Dies must withstand high stresses and be designed for the desired shape. Process variables like temperature, extrusion ratio, and friction affect the required extrusion force. Hot extrusion near 50-75% of melting temperature is most common to reduce deformation resistance.
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.
Forging is the process of shaping metals by applying compressive forces. It can be done either hot or cold. Common forging operations include drawing, piercing, punching, and swaging. Forging machines include drop hammers, power hammers, mechanical presses, and hydraulic presses. Closed-die forging uses dies to precisely shape parts, while open-die forging uses simpler dies. Proper die material selection and coatings can increase die life. Forging results in an elongated grain structure and improved mechanical properties compared to casting.
Extrusion is a process that uses pressure to force heated metal material through a die to create parts with a constant cross-section. There are two main types of extrusion: direct and indirect. Direct extrusion involves pushing the material through the die in the same direction as the ram movement, while indirect extrusion moves the material in the opposite direction of the ram. Extrusion can be performed hot or cold depending on the material, with hot extrusion allowing for more complex shapes from more readily extrudable metals like aluminum. Proper die material and lubrication are important for reducing friction during extrusion.
The document discusses various aspects of extrusion, a manufacturing process where a block of metal is forced to flow through a die opening. It describes different types of extrusion like hot and cold, direct and indirect, lubricated and hydrostatic. It also discusses defects in extrusion and the drawing process which is similar but uses a pulling force. The key information provided includes how extrusion allows shaping of solid and hollow metal sections, the operating principles and classifications of extrusion, and factors that affect the extrusion force.
The document discusses the extrusion manufacturing process. Extrusion involves forcing a block of metal through a die to create solid or hollow shapes. There are different types of extrusion classified by direction (direct, indirect), operating temperature (hot, cold), and equipment (horizontal, vertical). Hot extrusion is done at high temperatures using lubrication while cold extrusion is done at room temperature. The document also discusses defects, drawing as a related process, and factors that affect extrusion forces.
This document provides information on various forging processes and equipment. It discusses open die forging, impression forging, precision forging, and defines standard forging terminology. It describes various forging operations like upsetting, edging, fullering, drawing, swaging, piercing, punching, bending, roll forging, and skew rolling. It also discusses cogging, forging between dies, precision forging, die inserts, swaging, rotary swaging, tube swaging, and coining. The document outlines different types of forging machines like hammers, presses, screw presses and their characteristics. It concludes by listing common forging defects.
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.
Extrusion is a process where a block of metal is reduced in cross-section by forcing it to flow through a die under high pressure. There are different types of extrusion classified by direction (direct/indirect), temperature (hot/cold), and equipment (horizontal/vertical presses). Key equipment includes presses, dies, and tools. Dies must withstand high stresses and be designed for the desired shape. Process variables like temperature, extrusion ratio, and friction affect the required extrusion force. Hot extrusion near 50-75% of melting temperature is most common to reduce deformation resistance.
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.
Forging is the process of shaping metals by applying compressive forces. It can be done either hot or cold. Common forging operations include drawing, piercing, punching, and swaging. Forging machines include drop hammers, power hammers, mechanical presses, and hydraulic presses. Closed-die forging uses dies to precisely shape parts, while open-die forging uses simpler dies. Proper die material selection and coatings can increase die life. Forging results in an elongated grain structure and improved mechanical properties compared to casting.
Extrusion is a process that uses pressure to force heated metal material through a die to create parts with a constant cross-section. There are two main types of extrusion: direct and indirect. Direct extrusion involves pushing the material through the die in the same direction as the ram movement, while indirect extrusion moves the material in the opposite direction of the ram. Extrusion can be performed hot or cold depending on the material, with hot extrusion allowing for more complex shapes from more readily extrudable metals like aluminum. Proper die material and lubrication are important for reducing friction during extrusion.
The document discusses various aspects of extrusion, a manufacturing process where a block of metal is forced to flow through a die opening. It describes different types of extrusion like hot and cold, direct and indirect, lubricated and hydrostatic. It also discusses defects in extrusion and the drawing process which is similar but uses a pulling force. The key information provided includes how extrusion allows shaping of solid and hollow metal sections, the operating principles and classifications of extrusion, and factors that affect the extrusion force.
The document discusses the extrusion manufacturing process. Extrusion involves forcing a block of metal through a die to create solid or hollow shapes. There are different types of extrusion classified by direction (direct, indirect), operating temperature (hot, cold), and equipment (horizontal, vertical). Hot extrusion is done at high temperatures using lubrication while cold extrusion is done at room temperature. The document also discusses defects, drawing as a related process, and factors that affect extrusion forces.
This document summarizes the extrusion manufacturing process. Extrusion involves forcing a block of metal through a die opening to produce solid or hollow sections. It can be performed hot or cold, and produces parts through direct or indirect methods. Key advantages are producing complex shapes efficiently in small batches, though high costs and potential defects exist. The document also briefly outlines the related drawing process of pulling wire or tubing through a die to reduce its cross-section.
The document discusses various metal forming processes including rolling, forging, extrusion, and sheet metal working. It provides details on:
- Hot and cold working processes for forming metals like rolling, forging, and extrusion. These processes involve changing the shape of metals above or below their recrystallization temperature.
- Different types of rolling mills and how rolling changes the grain structure and properties of metals.
- The basic process of extrusion using direct or indirect methods to form materials into fixed cross-sections.
- Common forming techniques like deep drawing, bending, spinning, and drawing used to work sheet metals.
The document discusses various metal forming processes including hot working and cold working of metals. It describes processes like forging, rolling, extrusion, drawing, and spinning. Forging can be done through open die forging or closed die forging using various machines. It involves operations like upsetting, drawing down, punching, bending, and forging welding. Rolling involves processes like flat rolling and shape rolling. Extrusion can be done through hot or cold working. The document compares the characteristics and advantages and limitations of hot working versus cold working of metals.
This document provides an overview of forging processes and principles. It discusses various forging operations like smith forging, hammer forging, press forging, and roll forging. It also covers forging classification based on temperature (hot, warm, cold forging) and die arrangement (open, closed die forging). Common forging defects and applications in industries like automotive and aerospace are summarized.
This document discusses various metal forming processes including:
1. Hot and cold working processes such as forging, rolling, extrusion, and drawing. Forging can be open die, impression die, or closed die. Rolling can be flat or shape rolling.
2. The advantages of hot working include lower forces required, ability to produce dramatic shape changes, and potential to combine with casting. Cold working provides better surface finish and precision.
3. Extrusion uses compression to force metal through a die opening. It can produce hollow or complex cross-sections. Wire and bar drawing similarly reduce cross-section by pulling metal through a die.
This document provides an overview of various metal forming processes including rolling, extrusion, drawing, forging, bending, punching, blanking, deep drawing, and stretch forming. It discusses the basic mechanisms, types, defects, and forces involved in each process. Key points covered include how rolling reduces thickness through plastic deformation between rolls, the differences between direct and indirect extrusion, how drawing reduces cross-sectional area by pulling metal through a die, and common defects that can occur in deep drawing like wrinkling, tearing, and earing.
This document discusses various metal forming processes including forging, rolling, drawing, and extrusion. It provides details on hot working and cold working metals, types of forging machines and operations, flat and shape rolling, defects in rolled parts, principles of drawing rods, tubes and wires, and types of extrusion such as hot and cold extrusion. The key advantages and disadvantages of these metal forming techniques are also summarized.
Extrusion is a process where a block of metal is forced to flow through a die to reduce its cross-section. It is commonly used to produce cylindrical bars, tubes, or stock for other processes. Most metals require hot extrusion due to the large forces. Extrusion produces products with uniform properties and microstructure. Common extrusion defects include cracking, non-uniform deformation, and variations in grain structure. Extrusion equipment includes hydraulic presses in horizontal or vertical orientations and dies made of hardened tool steel. Process parameters like temperature, speed, and lubrication affect the required extrusion pressure.
Metal forming processes involve hot working and cold working of metals. Hot working involves mechanically working metals above their recrystallization temperature through processes like forging, rolling, extrusion, drawing, and spinning. Forging is done using open die forging or closed die forging. Common forging operations include upsetting, drawing down, blocking, fullering, and cutting. Cold working is done below the recrystallization temperature through processes like drawing, squeezing, and bending. Defects in forged metal parts can include cracking, laps, cold shuts, warping, and improperly formed sections.
The document discusses various metal forming processes including forging, rolling, extrusion, and drawing. It describes the key characteristics of these processes. Forging involves shaping metals using compressive forces and can be done hot or cold. Rolling is used to reduce the thickness and increase the length of metal by passing it through rotating cylinders. Extrusion forces heated metal through a die to take on the die's shape. Drawing reduces the cross-sectional area and increases the length of metal as it is pulled through a die. The document provides details on specific types and equipment used for each of these key metal forming techniques.
The document discusses various metal forming processes including forging, rolling, extrusion, and drawing. It describes the key characteristics of these processes. Forging involves shaping metals using compressive forces and can be done hot or cold. Rolling is used to reduce the thickness and alter the shape of metal strips and involves passing the metal between rolls. Extrusion uses either hot or cold compression to push metal through a die to take on a continuous cross-section. Drawing reduces the cross-sectional area and increases the length of metals by pulling them through a die.
Extrusion is a process where a billet is compressed and forced to flow through a die opening, acquiring the shape of the opening. In direct extrusion, the billet is pushed through the die by a ram. Indirect extrusion uses backward flow where the die is fixed to the ram and the billet flows in the opposite direction of ram movement. Extrusion can produce a variety of cross-sectional shapes from metals like aluminum, copper, steel, and plastics. Drawing is a similar process where a wire or rod is pulled rather than pushed through a die to reduce its cross-sectional area.
This document discusses various metal forming processes including forging, rolling, drawing, and extrusion. It provides details on:
1) Hot and cold working of metals, types of forging processes, characteristics of forging, types of forging machines, and common forging operations.
2) Types of rolling mills and rolling processes like flat strip rolling and shape rolling. It also discusses defects in rolled parts.
3) Principles and types of drawing and extrusion processes. Drawing processes include wire, rod, tube, and deep drawing. Extrusion can be hot or cold.
The document summarizes the rolling process. It defines rolling as plastically deforming metal by passing it between rolls. Rolling provides close dimensional control and high production. There are two main types: hot rolling and cold rolling. The document describes various rolling terminologies, mill products, defects, and different rolling processes like hot rolling, cold rolling, shaped rolling, and thread rolling. It also discusses factors like angle of contact, forces involved, and how to control flatness.
The document discusses the rolling process for metal forming. Rolling is defined as passing metal between rolls to plastically deform it. There are two main types: hot rolling, which is used for initial breakdown of ingots, and cold rolling, which provides closer dimensional tolerances and better surface finishes. Rolling can produce products like plate, sheet, strip, bars, and pipes. The rolling process involves passing metal through sets of rolls under high compressive forces.
This document provides an overview of forging processes and equipment. It discusses the classification of forging into open die and closed die forging. Open die forging involves compressing metal between flat or simple shaped dies, while closed die forging uses shaped dies to form the final part geometry. The document also describes common forging operations, equipment like hammers, presses, and defects that can occur during forging. It provides examples of industrial forging applications and factors that influence the forging process.
Metal forming process, Non chip forming machining processSuyog Lokhande
Mechanical forming processes include rolling, forging, and extrusion. Rolling involves passing metal through opposing rollers to reduce thickness. Forging involves compressing metal between dies or a hammer to shape it. Extrusion uses a container and die to force metal through an opening to create a shape. These processes deform metal through compression and are used to make common parts like gears, aircraft components, and tubing.
Metal forming processes like extrusion, drawing, bending and shearing are discussed. Extrusion involves compressing metal inside a chamber and forcing it through a die. Direct and indirect extrusion are described. Drawing involves pulling metal through a die to reduce its cross-section. Deep drawing forms cylindrical or box shapes from sheet metal. Shearing uses a punch and die to cut sheet metal. Bending forms shapes by curving sheet metal around a bend line without failure. Defects like surface cracking and piping in extrusion are also summarized.
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.
This document summarizes the extrusion manufacturing process. Extrusion involves forcing a block of metal through a die opening to produce solid or hollow sections. It can be performed hot or cold, and produces parts through direct or indirect methods. Key advantages are producing complex shapes efficiently in small batches, though high costs and potential defects exist. The document also briefly outlines the related drawing process of pulling wire or tubing through a die to reduce its cross-section.
The document discusses various metal forming processes including rolling, forging, extrusion, and sheet metal working. It provides details on:
- Hot and cold working processes for forming metals like rolling, forging, and extrusion. These processes involve changing the shape of metals above or below their recrystallization temperature.
- Different types of rolling mills and how rolling changes the grain structure and properties of metals.
- The basic process of extrusion using direct or indirect methods to form materials into fixed cross-sections.
- Common forming techniques like deep drawing, bending, spinning, and drawing used to work sheet metals.
The document discusses various metal forming processes including hot working and cold working of metals. It describes processes like forging, rolling, extrusion, drawing, and spinning. Forging can be done through open die forging or closed die forging using various machines. It involves operations like upsetting, drawing down, punching, bending, and forging welding. Rolling involves processes like flat rolling and shape rolling. Extrusion can be done through hot or cold working. The document compares the characteristics and advantages and limitations of hot working versus cold working of metals.
This document provides an overview of forging processes and principles. It discusses various forging operations like smith forging, hammer forging, press forging, and roll forging. It also covers forging classification based on temperature (hot, warm, cold forging) and die arrangement (open, closed die forging). Common forging defects and applications in industries like automotive and aerospace are summarized.
This document discusses various metal forming processes including:
1. Hot and cold working processes such as forging, rolling, extrusion, and drawing. Forging can be open die, impression die, or closed die. Rolling can be flat or shape rolling.
2. The advantages of hot working include lower forces required, ability to produce dramatic shape changes, and potential to combine with casting. Cold working provides better surface finish and precision.
3. Extrusion uses compression to force metal through a die opening. It can produce hollow or complex cross-sections. Wire and bar drawing similarly reduce cross-section by pulling metal through a die.
This document provides an overview of various metal forming processes including rolling, extrusion, drawing, forging, bending, punching, blanking, deep drawing, and stretch forming. It discusses the basic mechanisms, types, defects, and forces involved in each process. Key points covered include how rolling reduces thickness through plastic deformation between rolls, the differences between direct and indirect extrusion, how drawing reduces cross-sectional area by pulling metal through a die, and common defects that can occur in deep drawing like wrinkling, tearing, and earing.
This document discusses various metal forming processes including forging, rolling, drawing, and extrusion. It provides details on hot working and cold working metals, types of forging machines and operations, flat and shape rolling, defects in rolled parts, principles of drawing rods, tubes and wires, and types of extrusion such as hot and cold extrusion. The key advantages and disadvantages of these metal forming techniques are also summarized.
Extrusion is a process where a block of metal is forced to flow through a die to reduce its cross-section. It is commonly used to produce cylindrical bars, tubes, or stock for other processes. Most metals require hot extrusion due to the large forces. Extrusion produces products with uniform properties and microstructure. Common extrusion defects include cracking, non-uniform deformation, and variations in grain structure. Extrusion equipment includes hydraulic presses in horizontal or vertical orientations and dies made of hardened tool steel. Process parameters like temperature, speed, and lubrication affect the required extrusion pressure.
Metal forming processes involve hot working and cold working of metals. Hot working involves mechanically working metals above their recrystallization temperature through processes like forging, rolling, extrusion, drawing, and spinning. Forging is done using open die forging or closed die forging. Common forging operations include upsetting, drawing down, blocking, fullering, and cutting. Cold working is done below the recrystallization temperature through processes like drawing, squeezing, and bending. Defects in forged metal parts can include cracking, laps, cold shuts, warping, and improperly formed sections.
The document discusses various metal forming processes including forging, rolling, extrusion, and drawing. It describes the key characteristics of these processes. Forging involves shaping metals using compressive forces and can be done hot or cold. Rolling is used to reduce the thickness and increase the length of metal by passing it through rotating cylinders. Extrusion forces heated metal through a die to take on the die's shape. Drawing reduces the cross-sectional area and increases the length of metal as it is pulled through a die. The document provides details on specific types and equipment used for each of these key metal forming techniques.
The document discusses various metal forming processes including forging, rolling, extrusion, and drawing. It describes the key characteristics of these processes. Forging involves shaping metals using compressive forces and can be done hot or cold. Rolling is used to reduce the thickness and alter the shape of metal strips and involves passing the metal between rolls. Extrusion uses either hot or cold compression to push metal through a die to take on a continuous cross-section. Drawing reduces the cross-sectional area and increases the length of metals by pulling them through a die.
Extrusion is a process where a billet is compressed and forced to flow through a die opening, acquiring the shape of the opening. In direct extrusion, the billet is pushed through the die by a ram. Indirect extrusion uses backward flow where the die is fixed to the ram and the billet flows in the opposite direction of ram movement. Extrusion can produce a variety of cross-sectional shapes from metals like aluminum, copper, steel, and plastics. Drawing is a similar process where a wire or rod is pulled rather than pushed through a die to reduce its cross-sectional area.
This document discusses various metal forming processes including forging, rolling, drawing, and extrusion. It provides details on:
1) Hot and cold working of metals, types of forging processes, characteristics of forging, types of forging machines, and common forging operations.
2) Types of rolling mills and rolling processes like flat strip rolling and shape rolling. It also discusses defects in rolled parts.
3) Principles and types of drawing and extrusion processes. Drawing processes include wire, rod, tube, and deep drawing. Extrusion can be hot or cold.
The document summarizes the rolling process. It defines rolling as plastically deforming metal by passing it between rolls. Rolling provides close dimensional control and high production. There are two main types: hot rolling and cold rolling. The document describes various rolling terminologies, mill products, defects, and different rolling processes like hot rolling, cold rolling, shaped rolling, and thread rolling. It also discusses factors like angle of contact, forces involved, and how to control flatness.
The document discusses the rolling process for metal forming. Rolling is defined as passing metal between rolls to plastically deform it. There are two main types: hot rolling, which is used for initial breakdown of ingots, and cold rolling, which provides closer dimensional tolerances and better surface finishes. Rolling can produce products like plate, sheet, strip, bars, and pipes. The rolling process involves passing metal through sets of rolls under high compressive forces.
This document provides an overview of forging processes and equipment. It discusses the classification of forging into open die and closed die forging. Open die forging involves compressing metal between flat or simple shaped dies, while closed die forging uses shaped dies to form the final part geometry. The document also describes common forging operations, equipment like hammers, presses, and defects that can occur during forging. It provides examples of industrial forging applications and factors that influence the forging process.
Metal forming process, Non chip forming machining processSuyog Lokhande
Mechanical forming processes include rolling, forging, and extrusion. Rolling involves passing metal through opposing rollers to reduce thickness. Forging involves compressing metal between dies or a hammer to shape it. Extrusion uses a container and die to force metal through an opening to create a shape. These processes deform metal through compression and are used to make common parts like gears, aircraft components, and tubing.
Metal forming processes like extrusion, drawing, bending and shearing are discussed. Extrusion involves compressing metal inside a chamber and forcing it through a die. Direct and indirect extrusion are described. Drawing involves pulling metal through a die to reduce its cross-section. Deep drawing forms cylindrical or box shapes from sheet metal. Shearing uses a punch and die to cut sheet metal. Bending forms shapes by curving sheet metal around a bend line without failure. Defects like surface cracking and piping in extrusion are also summarized.
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.
Similar to Forging document for mechanical engineering students (20)
We recently hosted the much-anticipated Community Skill Builders Workshop during our June online meeting. This event was a culmination of six months of listening to your feedback and crafting solutions to better support your PMI journey. Here’s a look back at what happened and the exciting developments that emerged from our collaborative efforts.
A Gathering of Minds
We were thrilled to see a diverse group of attendees, including local certified PMI trainers and both new and experienced members eager to contribute their perspectives. The workshop was structured into three dynamic discussion sessions, each led by our dedicated membership advocates.
Key Takeaways and Future Directions
The insights and feedback gathered from these discussions were invaluable. Here are some of the key takeaways and the steps we are taking to address them:
• Enhanced Resource Accessibility: We are working on a new, user-friendly resource page that will make it easier for members to access training materials and real-world application guides.
• Structured Mentorship Program: Plans are underway to launch a mentorship program that will connect members with experienced professionals for guidance and support.
• Increased Networking Opportunities: Expect to see more frequent and varied networking events, both virtual and in-person, to help you build connections and foster a sense of community.
Moving Forward
We are committed to turning your feedback into actionable solutions that enhance your PMI journey. This workshop was just the beginning. By actively participating and sharing your experiences, you have helped shape the future of our Chapter’s offerings.
Thank you to everyone who attended and contributed to the success of the Community Skill Builders Workshop. Your engagement and enthusiasm are what make our Chapter strong and vibrant. Stay tuned for updates on the new initiatives and opportunities to get involved. Together, we are building a community that supports and empowers each other on our PMI journeys.
Stay connected, stay engaged, and let’s continue to grow together!
About PMI Silver Spring Chapter
We are a branch of the Project Management Institute. We offer a platform for project management professionals in Silver Spring, MD, and the DC/Baltimore metro area. Monthly meetings facilitate networking, knowledge sharing, and professional development. For more, visit pmissc.org.
LinkedIn for Your Job Search June 17, 2024Bruce Bennett
This webinar helps you understand and navigate your way through LinkedIn. Topics covered include learning the many elements of your profile, populating your work experience history, and understanding why a profile is more than just a resume. You will be able to identify the different features available on LinkedIn and where to focus your attention. We will teach how to create a job search agent on LinkedIn and explore job applications on LinkedIn.
5 key differences between Hard skill and Soft skillsRuchiRathor2
𝐓𝐡𝐞 𝐏𝐞𝐫𝐟𝐞𝐜𝐭 𝐁𝐥𝐞𝐧𝐝:
𝐖𝐡𝐲 𝐘𝐨𝐮 𝐍𝐞𝐞𝐝 𝐁𝐨𝐭𝐡 𝐇𝐚𝐫𝐝 & 𝐒𝐨𝐟𝐭 𝐒𝐤𝐢𝐥𝐥𝐬 𝐭𝐨 𝐓𝐡𝐫𝐢𝐯𝐞 💯
In today's dynamic and competitive market, a well-rounded skillset is no longer a luxury - it's a necessity.
While technical expertise (hard skills) is crucial for getting your foot in the door, it's the combination of hard and soft skills that propels you towards long-term success and career advancement. ✨
Think of it like this: Imagine a highly skilled carpenter with a masterful understanding of woodworking (hard skills). But if they struggle to communicate effectively with clients, collaborate with builders, or adapt to project changes (soft skills), their true potential remains untapped. 😐
The synergy between hard and soft skills is what creates true value in the workplace. Strong communication allows you to clearly articulate your technical expertise, while problem-solving skills help you navigate complex challenges alongside your team. 💫
By actively developing both sets of skills, you position yourself as a well-rounded professional who can not only perform tasks efficiently but also contribute meaningfully to a collaborative and dynamic work environment.
Go through the carousel and let me know your views 🤩
I am an accomplished and driven administrative management professional with a proven track record of supporting senior executives and managing administrative teams. I am skilled in strategic planning, project management, and organizational development, and have extensive experience in improving processes, enhancing productivity, and implementing solutions to support business objectives and growth.
Learnings from Successful Jobs SearchersBruce Bennett
Are you interested to know what actions help in a job search? This webinar is the summary of several individuals who discussed their job search journey for others to follow. You will learn there are common actions that helped them succeed in their quest for gainful employment.
21. Forging is a metal working process in which useful
shape is obtained in solid state by hammering or
pressing metal.
FORGING – OPERATIONS AND
CLASSIFICATIONS
1. Upsetting
22. 2. Edging
Ends of the bar are shaped to requirement
using edging dies.
27. 7. Punching
It is a cutting operation in which a required
hole is produced using a punching die.
8. Bending: The metal is bent around a die/anvil.
28. Roll forging
In this process, the bar stock is reduced in cross-section or
undergoes change in cross-section when it is passed through
a pair of grooved rolls made of die steel.
This process serves as the initial processing step for forging
of parts such as connecting rod, crank shaft etc.
29. A particular type of roll forging called skew rolling is
used for making spherical balls for ball bearings
SKEW ROLLING
30. Cogging
Successively reducing the thickness of a bar with
open die forging
• Also called drawing out
• Reducing the thickness of a long section of a bar
without excessive forces or machining
31. Forging between two shaped dies
• Fullering and Edging distribute material into
specific regions of the blank
• Blocking creates a rough shape
32. Precision Forging
• True closed die or
flashless forging uses
precise volumes of
material to
completely fill the
die cavity
33. • Undersize blanks will not fill the cavity, oversize
blanks will cause high pressures and may damage
the dies
• • Reduces the number of additional operations
and wasted material
• • Near-net-shape forging (or net-shape)
39. Rotary swaging or radial forging and
Tube swaging
• A solid rod or tube is subjected to
radial impact forces by reciprocating
dies (workpiece is stationary)
• Screwdriver blades made this way
40.
41. • Coining is for minting
coins and jewelry
• Completely closed dies
and high pressures (5-6
times the strength of the
material) to obtain fine
details
• Lubricants cannot be
used since they are
incompressible
COINING
42. An example of a coining operation to produce an
impression of the letter E
43. Die Design
Must know workpiece material strength and ductility,
deformation rate, temperature sensitivity, frictional
characteristics
Forgeability of materials is capability to undergo
deformation without cracking
Must evaluate shape, size, and complexity of design
Material flows in the direction of least resistance, which
is why intermediate shapes may need to be formed
44. Preshaping should prevent material from easily
flowing into flash, produce favorable grain flow
patterns, and minimize friction and wear at the die-
workpiece interface
Computers can model and predict material flow
45. • Parting lines are usually at the largest cross section
• Flash specifications:
• Flash clearance should be 3% of maximum forging
thickness
• Land that is 2-5 times flash thickness, then a larger
gutter that does not restrict flash flow
46. • Draft angles are needed (7-10 deg internal, 3-5
external)
• Avoid small radii
• Avoid sharp corners
• Inserts can be used
47. Die materials must have strength and toughness at
elevated temperatures, hardenability, resistance to
mechanical and thermal shock, wear resistance
Die selection based on size, required properties,
forging temperature, operation type, cost, and
production quantities
Common die materials are tool and die steels with
chromium, nickel, molybdenum, and vanadium
48. Dies are forged from castings, and then machined
and finished as needed, often with heat treatment
to increase hardness and wear resistance
Lubricants act as thermal barriers for hot
workpiece and cooler dies, improve metal flow,
and are parting agents
49. Die Failure Causes
Improper design
Defective material
Improper heat treatment and finishing
operations
Overheating and cracks caused by temperature
cycling – usually preheat dies to 1500-2500
degrees Celsius
Excessive wear – chipping or cracking from
impact forces (can be repaired by welding or
laser metal deposition)
50. Overloading
Misuse or improper handling – failure to
remove a forged part before inserting a
new blank
51. Types of Forging Machine
Work Restricted Machines (Energy or Load
Limited) – Hammers
• Gravity drop hammers
• Power hammers
• Counterblow hammers – Friction Screw
Presses – Hydraulic Presses
• Stroke Limited (Restricted) Machines –
Mechanical presses
53. Mechanical board hammer
It is a stroke restricted machine.
• Repeatedly the board (weight) is raised by rolls
and is dropped on the die.
• Rating is in terms of weight of the ram and energy
delivered.
54.
55.
56. Steam Hammer (Power Hammer)
Range: 5 kN to 200 kN
• It uses steam in a piston and cylinder
arrangement.
• It has greater forging capacity.
• It can produce forgings ranging from a
few kgs to several tonnes.
• Preferred in closed die forging
58. It is a load restricted machine.
• It has more of squeezing action than hammering
action.
• Hence dies can be smaller and have longer life
than with a hammer.
Hydraulic press
59.
60. Features of Hydraulic Press
• Full press load is available during the full
stroke of the ram.
• Ram velocity can be controlled and varied
during the stroke.
• It is a slow speed machine and hence has
longer contact time and hence higher die
temperatures.
• The slow squeezing action gives close
tolerance on forgings.
• Initial cost is higher compared to hammers.
61. Mechanical press with an
eccentric drive; the
eccentric shaft can be
replaced by a crankshaft to
give the up - and -down
motion to the ram.
65. Forging Hammers
• Gravity Drop Hammers – drop forging with
a free falling ram; energy based on product of
ram’s weight and drop height
Ram weights of 180-4500 kg (400-10000 lbs)
• Power Drop Hammers – downstroke is
accelerated by steam, air, or hydraulic
pressure
Ram weights of 225-22500 kg
66. Counterblow Hammers – two rams that
approach each other horizontally or
vertically (part may be rotated between
successive blows); operate at high speeds
with less vibrations transmitted – very large
capacity possible
High Energy Rate Machines – ram
accelerated by an inert gas at high pressure;
very high speeds but problems with
maintenance, die breakage, and safety
68. Mechanical Presses
Mechanical Presses – crank or
eccentric shaft driven, or knuckle-joint
for very high forces; stroke limited
2.7-107 MN (300-14000 tons)
Higher production rates than
hammers
less blows More precise than
hammers
moving die plate guided by slide
ways or columns
69. Hydraulic Presses
Hydraulic Presses – constant
speeds, load limited, longer
processing times, higher initial
cost than mechanical presses
but require less maintenance
125 MN (14000 tons)
open die, 450 MN (50000
tons) closed die
70. Friction Screw Presses
Screw Presses –
flywheel driven, energy
limited (if dies do not
completely close, cycle
repeats)
• Small production
runs, high precision
• 1.4-280 MN (160-
31500 tons)
71.
72. FORGING DEFECTS
The different types of defects, occurring in the
forging operations are as follows:
1. Incomplete die filling.
2. Die misalignment.
3. Forging laps.
4. Incomplete forging penetration- should forge on
the press.
5. Microstructural differences resulting in
pronounced property variation.
6. Hot shortness, due to high sulphur concentration
in steel and nickel.
73. 7. Pitted surface, due to oxide scales occurring
at high temperature stick on the dies.
8. Buckling, in upsetting forging, due to high
compressive stress.
9. Surface cracking, due to temperature
differential between surface and center, or
excessive working of the surface at too low
temperature.
10. Micro cracking, due to residual stress.
77. EXTRUSION
HOT EXTRUSION COLD EXTRUSION
Forward or direct extrusion
Backward or indirect extrusion
Hooker Extrusion
Hydrostatic extrusion
Impact extrusion
78. Extrusion is a plastic deformation process
in which a block of metal (billet) is forced
to flow by compression through the die
opening of a smaller cross-sectional area
than that of the original billet
79. Extrusion is an indirect-compression process
Definition and principle of DIRECT extrusion
83. In indirect extrusion, the die at the front end of
the hollow stem moves relative to the container,
but there is no relative displacement between
the billet and the container.
Therefore, this process is characterized by the
absence of friction between the billet surface
and the container, and there is no displacement
of the billet center relative to the peripheral
regions.
90. Process variables in direct extrusion. The die
angle, reduction in cross section, extrusion
speed, billet temperature, lubrication all affect
the extrusion pressure.
91. Typical extrusion–die configurations: (a) die for
nonferrous metals; (b) die for ferrous metals; (c) die
for a T die for a T-shaped extrusion made of hot-work
die steel and used with molten glass as a lubricant
95. Extrusion
Defects
a) Centre-burst: internal crack due to excessive tensile
stress at the centre possibly because of high die angle,
low extrusion ratio.
b) Piping: sink hole at the end of billet under direct
extrusion.
c) Surface cracking: High part temperature due to low
extrusion speed and high strain rates.
96. Extrusion Force
Force, F, depends on:
Strength of billet material
Extrusion Ratio, R, Ao/Af
Friction between billet and chamber & die
surfaces
Process variables: temperature, velocity
F = A0k ln(A0/Af)
The Extrusion constant, k, is determined
experimentally.
98. Metal Flow in Extrusion
Influences quality & mechanical
properties of extruded product
Material flows longitudinally
Elongated grain structure
99. Types of metal flow in extruding with square dies.
(a) Flow pattern obtained at low friction or in indirect extrusion.
(b) Pattern obtained with high friction at the billet–chamber interfaces.
(c) Pattern obtained at high friction or with cooling of the outer regions of the billet in the
chamber. This type of pattern, observed in metals whose strength increases rapidly with
decreasing temperature, leads to a defect known as pipe (or extrusion) defect.
100. Use higher temperatures to improve ductility &
metal flow
Can cause excessive die wear, result of abrasion
from surface oxides
Can have non uniform deformation caused by
cooling surfaces of billet and die
Improve by preheating die
Surface oxides on product may be undesirable
when good surface finish is important
Can prevent extrusion of surface oxides by making
the diameter of the dummy block a little smaller
than the container; this keeps a thin shell (“skull”)
of oxides in the container
HOT EXTRUSION
101.
102. Extrusion of a seamless tube
(a)using an internal mandrel that moves independently
of the ram. (An alternative arrangement has the
mandrel integral with the ram.)
(b) using a spider die to produce seamless tubing.
103. Poor and good examples of cross sections to be extruded
Poor and good examples examples of cross sections sections
to be extruded extruded.
Note the importance of eliminating sharp corners and of
keeping section thicknesses uniform.
104. Lubrication
Useful in hot extrusion:
Material flow during extrusion
Surface finish & integrity
Product quality
Extrusion forces
Glass is excellent lubricant for:
Steels
Stainless steels
High-temperature metals & alloys
Glass applied as powder to billet surface or
Insert glass pad at die entrance; when heated, melted glass
lubricates die surface
105.
106. Cold Extrusion
Uses slugs cut from cold finished or hot rolled bars,
wire, or plates
Smaller slugs ( ≤ 40 mm or 1.5” 40 mm or 1.5”) are
sheared; ends squared if necessary
Larger slugs are machined to specific lengths
Stresses on tool dies are very high
Lubrication is critical, especially with steels
Apply phosphate-conversion coating on workpiece,
conversion coating on workpiece, followed by soap
or wax
107. Cold Extrusion
Force = F = 1.7Ao Yavg έ
Ao is cross sectional area of blank
Yavg is average flow stress of metal
έ is true strain that piece undergoes
= ln(Ao/Af )
109. Drawing
• Changing the cross-sectional area or shape of
a solid rod, wire, or tubing by pulling it through
a die
• Rod is the term for larger cross sections, wire
for smaller
• Typical products: Electrical wiring, Cable, Tension-
loaded structural members, Welding electrodes, Springs,
Paper clips, Bicycle wheel spokes, Musical instrument strings.
Die and mandrel materials typically tool steels (chromium
plated) and carbides (titanium nitride coated), diamond for
fine wire
110. Drawing Parameters
• Parameters include die angle (a), reduction in cross
sectional area, drawing speed, temperature, and lubrication
• For a certain reduction in diameter and friction conditions,
there is an optimum die angle
• Yavg is average true stress of the material in the die gap
• Die angle is typically 6-15 degrees
• Maximum reduction per pass is 63%, but more than 45%
can cause lubricant breakdown and surface-finish
deterioration
• The smaller the initial area, the smaller the reduction per
pass percentage that is typically used
• Intermediate annealing may be needed between passes
111.
112. In drawing, the cross section of a long rod or
wire is reduced or changed by pulling (hence
the term drawing) it through a die called a draw
die
113. Drawing Various Shapes • Drawing flat strips
(ironing) is used in making beverage cans •
Bundle drawing is used to simultaneously draw
thousands of wires with final polygonal cross
sectional shapes
114. Tube Drawing:
Drawing can be used to reduce the diameter or
wall thickness of seamless tubes and pipes, after
the initial tubing has been produced by some
other process such as extrusion.
Tube drawing can be carried out either with or
without a mandrel.
The simplest method uses no mandrel and is
used for diameter reduction.
The term tube sinking is sometimes applied to
this operation.
115. Examples of tube drawing operations, with and without an internal
mandrel. Note that a variety of diameters and wall thicknesses can
be produced from the same initial tube stock (which has been
made by other processes).
116. Wire sizes down to 0.03 mm (0.001 in) are
possible in wire drawing
Continuous drawing of wire
117. Wire drawing is done on continuous drawing
machines that consist of multiple draw dies,
separated by accumulating drums between
the dies.
Each drum, called a capstan, is motor driven
to provide the proper pull force to draw the
wire stock through the upstream die.
It also maintains a modest tension on the
wire as it proceeds to the next draw die in
the series.
118. Each die provides a certain amount of
reduction in the wire, so that the desired
total reduction is achieved by the series.
Depending on the metal to be processed
and the total reduction, annealing of the wire
is sometimes required between groups of
dies in the series.
