The document discusses various types of forging processes including open die forging, impression die forging, and flashless forging. Open die forging involves compressing metal between flat dies, allowing lateral flow. Impression die forging uses dies with cavities to impart shapes, constraining flow. Flashless forging completely fills dies with no excess flash. Forging is used to make strong components for industries like automotive and aerospace. Equipment includes forging hammers that apply impact and presses that apply gradual pressure.
Rolling is a metal forming process that uses rolls to reduce the thickness and increase the length of metal workpieces. It can be done hot or cold. Hot rolling occurs above the metal's recrystallization temperature and results in a more uniform structure, while cold rolling occurs at room temperature and produces closer tolerances and a better surface finish. The document defines various products of rolling like billets, blooms, slabs, plates, sheets and strips based on their dimensions. It also describes different types of rolling processes like continuous, transverse, shape, ring and thread rolling as well as the types of mills used like two-high, three-high and four-high mills.
This document discusses common casting defects such as surface defects, internal defects, incorrect chemical composition, and unsatisfactory mechanical properties. It defines casting defects and explains how they reduce output and increase production costs. Specific defects covered include swell, fins, gas holes, shrinkage cavities, hot tears, and cold shuts. For each defect, the causes and remedies are described. Even in modern foundries, the rejection rate can be as high as 20% of total castings produced due to these defects.
The document provides an overview of the extrusion process for metals. It discusses different types of extrusion including direct/indirect, hot/cold, and hydrostatic extrusion. It also covers extruding tubes and pipes. Key points include:
- Extrusion involves pushing heated metal billets through a die to reduce the cross-section and shape the material.
- Direct extrusion uses a stationary container and moving ram, while indirect uses a stationary die and moving container.
- Hot extrusion is done at 50-75% melting temperature for better formability, while cold extrusion is at or near room temperature.
- Hydrostatic extrusion surrounds the billet with pressurized
The document discusses various defects that can occur in metal forming processes. It describes the different types of bulk metal forming processes like rolling, forging, extrusion, and drawing. It also covers sheet metalworking processes like bending, drawing, and shearing. The document discusses factors that influence metal forming like material behavior, temperature, strain rate, friction, and lubrication. It explains defects like springback, wrinkles, and provides methods to minimize them.
The document discusses the powder metallurgy process which consists of three main steps: 1) blending and mixing of metal powders and additives, 2) compaction of the blended powder using pressure-based or pressureless techniques, and 3) sintering the compacted powder below the melting point to bond the particles together without melting. Optional secondary operations such as heat treatment, machining or infiltration can further process the sintered parts.
Investment casting is an ancient metal forming technique dating back 5000 years. It involves creating a ceramic mold by coating a wax pattern and allowing it to harden. The wax is then melted out and molten metal is poured in, after which the ceramic mold is broken away. Key steps include preparing wax patterns, applying ceramic coats, dewaxing, burnout, metal pouring, and removal from the mold. Investment casting is used to make complex, high-precision parts for industries like aerospace, firearms, medical implants, and valves. It allows for intricate shapes and tight tolerances at relatively low material waste.
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.
1. Shell casting involves making a shell mold by applying a mixture of sand and thermosetting resin to a heated metal pattern. This allows for casting of parts with complex shapes and good surface finish tolerance.
2. Investment casting, also called lost-wax casting, involves making a wax pattern that is coated with refractory material to form a ceramic mold, melting out the wax to leave a cavity for molten metal. This enables production of parts with intricate details and close tolerances.
3. Die casting uses high pressure to force molten metal into molds, allowing precise replication of complex shapes. It is well-suited for producing parts from non-ferrous alloys in high volumes.
Rolling is a metal forming process that uses rolls to reduce the thickness and increase the length of metal workpieces. It can be done hot or cold. Hot rolling occurs above the metal's recrystallization temperature and results in a more uniform structure, while cold rolling occurs at room temperature and produces closer tolerances and a better surface finish. The document defines various products of rolling like billets, blooms, slabs, plates, sheets and strips based on their dimensions. It also describes different types of rolling processes like continuous, transverse, shape, ring and thread rolling as well as the types of mills used like two-high, three-high and four-high mills.
This document discusses common casting defects such as surface defects, internal defects, incorrect chemical composition, and unsatisfactory mechanical properties. It defines casting defects and explains how they reduce output and increase production costs. Specific defects covered include swell, fins, gas holes, shrinkage cavities, hot tears, and cold shuts. For each defect, the causes and remedies are described. Even in modern foundries, the rejection rate can be as high as 20% of total castings produced due to these defects.
The document provides an overview of the extrusion process for metals. It discusses different types of extrusion including direct/indirect, hot/cold, and hydrostatic extrusion. It also covers extruding tubes and pipes. Key points include:
- Extrusion involves pushing heated metal billets through a die to reduce the cross-section and shape the material.
- Direct extrusion uses a stationary container and moving ram, while indirect uses a stationary die and moving container.
- Hot extrusion is done at 50-75% melting temperature for better formability, while cold extrusion is at or near room temperature.
- Hydrostatic extrusion surrounds the billet with pressurized
The document discusses various defects that can occur in metal forming processes. It describes the different types of bulk metal forming processes like rolling, forging, extrusion, and drawing. It also covers sheet metalworking processes like bending, drawing, and shearing. The document discusses factors that influence metal forming like material behavior, temperature, strain rate, friction, and lubrication. It explains defects like springback, wrinkles, and provides methods to minimize them.
The document discusses the powder metallurgy process which consists of three main steps: 1) blending and mixing of metal powders and additives, 2) compaction of the blended powder using pressure-based or pressureless techniques, and 3) sintering the compacted powder below the melting point to bond the particles together without melting. Optional secondary operations such as heat treatment, machining or infiltration can further process the sintered parts.
Investment casting is an ancient metal forming technique dating back 5000 years. It involves creating a ceramic mold by coating a wax pattern and allowing it to harden. The wax is then melted out and molten metal is poured in, after which the ceramic mold is broken away. Key steps include preparing wax patterns, applying ceramic coats, dewaxing, burnout, metal pouring, and removal from the mold. Investment casting is used to make complex, high-precision parts for industries like aerospace, firearms, medical implants, and valves. It allows for intricate shapes and tight tolerances at relatively low material waste.
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.
1. Shell casting involves making a shell mold by applying a mixture of sand and thermosetting resin to a heated metal pattern. This allows for casting of parts with complex shapes and good surface finish tolerance.
2. Investment casting, also called lost-wax casting, involves making a wax pattern that is coated with refractory material to form a ceramic mold, melting out the wax to leave a cavity for molten metal. This enables production of parts with intricate details and close tolerances.
3. Die casting uses high pressure to force molten metal into molds, allowing precise replication of complex shapes. It is well-suited for producing parts from non-ferrous alloys in high volumes.
This document discusses various sheet metal forming processes and related topics. It begins by outlining some key metal characteristics that affect sheet metal processing, such as elongation, anisotropy, grain size, and residual stress. It then describes basic sheet metal processes like cutting, bending, drawing, and various specific processes like roll forming, spinning, and super plastic forming. The document provides details on processes like shearing, punching, bending, deep drawing, and stretch forming. It also discusses topics such as formability tests, springback, necking, and methods for measuring strain in sheet metal.
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.
- Shell moulding is an efficient and economical casting method that uses a resin-sand mixture to form a thin "shell" around a heated pattern. This shell is then used as the mold cavity.
- Investment casting, also called lost-wax casting, is an ancient casting process used to produce complex shapes. It involves creating a wax pattern, coating it with refractory materials to form a ceramic "shell" mold, heating to remove the wax, and pouring molten metal into the shell. This allows for net-shape casting of intricate parts.
- Pressure die casting is a high-pressure casting process where molten metal is injected into steel dies to form castings. It is well-su
Stretch forming is a manufacturing process where sheet metal is stretched and bent simultaneously over a die to form large contoured parts. It is performed on a stretch press, where the sheet metal is gripped along the edges by jaws attached to carriages that stretch the sheet against a contoured form die. Special forming processes include hydro forming, where hydraulic fluid acts as a flexible die; rubber pad forming, where sheet metal is pressed between a die and rubber block; and metal spinning, where force is applied to sheet metal wrapped over a rotating mandrel to take its shape.
Rolling is a metal forming process where metal stock is passed through one or more pairs of rolls to reduce the thickness and change the cross section of the metal. There are both hot and cold rolling processes. The metal is compressed between the rolls through frictional forces, changing the shape of the metal. Rolling processes can produce shapes like plates, sheets, rods, bars, pipes and rails. Rolling mills can have two, three, four or multiple rolls depending on the specific application and required shape. Rolling is used to mass produce metal products and form complex cross sections.
1. The document discusses various metal casting processes and sand casting in particular. It describes the basic steps in sand casting including mould making, pouring, cooling, and removal.
2. Sand is commonly used as the mould material due to its low cost. It requires binders like clay to give it strength and hold its shape. The properties of ideal moulding sand and types of sands for different applications are explained.
3. Key aspects of sand casting like advantages, disadvantages, and factors affecting the properties of moulding sand are summarized. Common tests to evaluate moulding sand quality are also mentioned.
Isostatic pressing is a powder metallurgy technique that applies equal pressure in all directions to compact powdered materials. There are three main types - cold isostatic pressing, hot isostatic pressing, and warm isostatic pressing. Isostatic pressing allows for high density and uniform compaction of materials without the need for lubricants. It can be used to compact difficult materials like superalloys. The global isostatic pressing market was valued at $5.72 billion in 2017 and is projected to reach $9.22 billion by 2023, growing at a CAGR of 8.08% due to increasing demand for high-density 3D printed parts and investment in aerospace and defense applications
Powder metallurgy is a process for manufacturing parts from metal powders by compacting and sintering. Key steps include producing metal powders through methods like atomization or chemical reduction, blending powders and lubricants, compacting the blended powder in a die under pressure to form a green compact, and sintering the compact at high temperatures to bond the powder particles. The sintered parts have properties that cannot be achieved through conventional manufacturing and the process allows for high precision and low waste production of simple parts.
This document discusses electrical discharge machining (EDM) and wire cut EDM. It begins with a brief history of EDM and an overview of the EDM process, including its working principle, important characteristics, and applications. It then focuses on wire cut EDM, explaining its working principle, major components of the process, advantages, and disadvantages. The document concludes by outlining the scope and plan for investigating the effects of process parameters on material removal rate, surface finish, and kerf width in wire cut EDM.
Blow Hole Defect Analysis in Die CastingRamesh Raja
This document summarizes an analysis of blow hole defects in die casting. The objectives were to minimize defects using design of experiments. Process parameters like metal temperature, die temperature, and die holding time were identified as factors affecting blow hole defects. Experiments were conducted using a Taguchi design with three factors at three levels. Analysis of variance showed die temperature was the most significant factor. Optimization found the best parameters were a metal temperature of 700°C, die temperature of 300°C, and die holding time of 75 seconds. This was predicted to increase casting density by 4.13% and reduce blow holes.
This document provides a 10-step overview of the cold rolling process for steel in a 4 Hi mill. The key steps include: 1) Pickling the hot rolled coil to remove impurities, 2) Water washing, 3) Applying a rust-protective emulsion, 4) Sizing coils to an ideal diameter for rolling, 5) Cold rolling the steel through multiple passes to reduce thickness, 6) Annealing to improve strength, 7) A final "skin pass" rolling, 8) Slitting coils to customer specifications, 9) Applying a protective coating, and 10) Packaging the finished cold rolled steel for shipping. The cold rolled steel can be used for automotive and appliance manufacturing.
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.
Manufacturing of bearing through powder metallurgyneeshu89sharma
This document discusses the manufacturing process of sintered metal self-lubricating bearings through powder metallurgy. It involves mixing elemental copper, tin, and graphite powders, compacting the powder mixture, sintering the compact to consolidate it, and post-sintering operations like sizing and impregnation to fill pores with oil. The sintered bearings provide self-lubrication through the absorption and release of oil from interconnected pores when heated during use.
The document discusses various aspects of solidification processes for pure metals and alloys. It covers topics such as solidification curves, grain structure formation, mushy zone formation in alloys, segregation of elements, shrinkage during solidification, and directional solidification techniques. It also discusses the functions and design of gating systems, including elements like pouring basins, sprues, runners, gates, and risers.
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.
The process of transformation of a substance from liquid to solid state in which the crystal lattice forms and crystals appear.
•Volume shrinkage or volume contraction
Molten steel is tapped into a ladle and alloying elements are added before being cast into molds. Steel ingots can have square, round, or polygon cross-sections depending on their intended use - squares for rolling, rectangles for flat products, and rounds for tubes. Ingot casting molds are made of cast iron and come in two types - wide end up or narrow end up. As the steel solidifies in the mold, it forms three distinct zones - a thin chill zone against the mold walls, columnar zones of elongated crystals perpendicular to the walls, and an inner equiaxed zone of larger isotropic crystals.
Strengthening Mechanisms of Metals and alloysDEVINDA MAHASEN
In this presentation, I have explained 4 types of strengthening processes of metals.
Grain-size reduction
Solid-solution alloying
Strain hardening (work hardening or cold working)
Annealing of deformed metals
The document discusses die casting, which is a permanent mold casting process where metal alloys such as aluminum, magnesium, and copper are poured into metal molds to produce a large number of identical castings. There are two main types of die casting: gravity die casting where molten metal is poured by hand into molds, and pressure die casting where molten metal is injected into molds under high pressure. Pressure die casting provides smoother, more dimensionally accurate castings and is used to manufacture small castings in industries.
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.
This document discusses various sheet metal forming processes and related topics. It begins by outlining some key metal characteristics that affect sheet metal processing, such as elongation, anisotropy, grain size, and residual stress. It then describes basic sheet metal processes like cutting, bending, drawing, and various specific processes like roll forming, spinning, and super plastic forming. The document provides details on processes like shearing, punching, bending, deep drawing, and stretch forming. It also discusses topics such as formability tests, springback, necking, and methods for measuring strain in sheet metal.
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.
- Shell moulding is an efficient and economical casting method that uses a resin-sand mixture to form a thin "shell" around a heated pattern. This shell is then used as the mold cavity.
- Investment casting, also called lost-wax casting, is an ancient casting process used to produce complex shapes. It involves creating a wax pattern, coating it with refractory materials to form a ceramic "shell" mold, heating to remove the wax, and pouring molten metal into the shell. This allows for net-shape casting of intricate parts.
- Pressure die casting is a high-pressure casting process where molten metal is injected into steel dies to form castings. It is well-su
Stretch forming is a manufacturing process where sheet metal is stretched and bent simultaneously over a die to form large contoured parts. It is performed on a stretch press, where the sheet metal is gripped along the edges by jaws attached to carriages that stretch the sheet against a contoured form die. Special forming processes include hydro forming, where hydraulic fluid acts as a flexible die; rubber pad forming, where sheet metal is pressed between a die and rubber block; and metal spinning, where force is applied to sheet metal wrapped over a rotating mandrel to take its shape.
Rolling is a metal forming process where metal stock is passed through one or more pairs of rolls to reduce the thickness and change the cross section of the metal. There are both hot and cold rolling processes. The metal is compressed between the rolls through frictional forces, changing the shape of the metal. Rolling processes can produce shapes like plates, sheets, rods, bars, pipes and rails. Rolling mills can have two, three, four or multiple rolls depending on the specific application and required shape. Rolling is used to mass produce metal products and form complex cross sections.
1. The document discusses various metal casting processes and sand casting in particular. It describes the basic steps in sand casting including mould making, pouring, cooling, and removal.
2. Sand is commonly used as the mould material due to its low cost. It requires binders like clay to give it strength and hold its shape. The properties of ideal moulding sand and types of sands for different applications are explained.
3. Key aspects of sand casting like advantages, disadvantages, and factors affecting the properties of moulding sand are summarized. Common tests to evaluate moulding sand quality are also mentioned.
Isostatic pressing is a powder metallurgy technique that applies equal pressure in all directions to compact powdered materials. There are three main types - cold isostatic pressing, hot isostatic pressing, and warm isostatic pressing. Isostatic pressing allows for high density and uniform compaction of materials without the need for lubricants. It can be used to compact difficult materials like superalloys. The global isostatic pressing market was valued at $5.72 billion in 2017 and is projected to reach $9.22 billion by 2023, growing at a CAGR of 8.08% due to increasing demand for high-density 3D printed parts and investment in aerospace and defense applications
Powder metallurgy is a process for manufacturing parts from metal powders by compacting and sintering. Key steps include producing metal powders through methods like atomization or chemical reduction, blending powders and lubricants, compacting the blended powder in a die under pressure to form a green compact, and sintering the compact at high temperatures to bond the powder particles. The sintered parts have properties that cannot be achieved through conventional manufacturing and the process allows for high precision and low waste production of simple parts.
This document discusses electrical discharge machining (EDM) and wire cut EDM. It begins with a brief history of EDM and an overview of the EDM process, including its working principle, important characteristics, and applications. It then focuses on wire cut EDM, explaining its working principle, major components of the process, advantages, and disadvantages. The document concludes by outlining the scope and plan for investigating the effects of process parameters on material removal rate, surface finish, and kerf width in wire cut EDM.
Blow Hole Defect Analysis in Die CastingRamesh Raja
This document summarizes an analysis of blow hole defects in die casting. The objectives were to minimize defects using design of experiments. Process parameters like metal temperature, die temperature, and die holding time were identified as factors affecting blow hole defects. Experiments were conducted using a Taguchi design with three factors at three levels. Analysis of variance showed die temperature was the most significant factor. Optimization found the best parameters were a metal temperature of 700°C, die temperature of 300°C, and die holding time of 75 seconds. This was predicted to increase casting density by 4.13% and reduce blow holes.
This document provides a 10-step overview of the cold rolling process for steel in a 4 Hi mill. The key steps include: 1) Pickling the hot rolled coil to remove impurities, 2) Water washing, 3) Applying a rust-protective emulsion, 4) Sizing coils to an ideal diameter for rolling, 5) Cold rolling the steel through multiple passes to reduce thickness, 6) Annealing to improve strength, 7) A final "skin pass" rolling, 8) Slitting coils to customer specifications, 9) Applying a protective coating, and 10) Packaging the finished cold rolled steel for shipping. The cold rolled steel can be used for automotive and appliance manufacturing.
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.
Manufacturing of bearing through powder metallurgyneeshu89sharma
This document discusses the manufacturing process of sintered metal self-lubricating bearings through powder metallurgy. It involves mixing elemental copper, tin, and graphite powders, compacting the powder mixture, sintering the compact to consolidate it, and post-sintering operations like sizing and impregnation to fill pores with oil. The sintered bearings provide self-lubrication through the absorption and release of oil from interconnected pores when heated during use.
The document discusses various aspects of solidification processes for pure metals and alloys. It covers topics such as solidification curves, grain structure formation, mushy zone formation in alloys, segregation of elements, shrinkage during solidification, and directional solidification techniques. It also discusses the functions and design of gating systems, including elements like pouring basins, sprues, runners, gates, and risers.
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.
The process of transformation of a substance from liquid to solid state in which the crystal lattice forms and crystals appear.
•Volume shrinkage or volume contraction
Molten steel is tapped into a ladle and alloying elements are added before being cast into molds. Steel ingots can have square, round, or polygon cross-sections depending on their intended use - squares for rolling, rectangles for flat products, and rounds for tubes. Ingot casting molds are made of cast iron and come in two types - wide end up or narrow end up. As the steel solidifies in the mold, it forms three distinct zones - a thin chill zone against the mold walls, columnar zones of elongated crystals perpendicular to the walls, and an inner equiaxed zone of larger isotropic crystals.
Strengthening Mechanisms of Metals and alloysDEVINDA MAHASEN
In this presentation, I have explained 4 types of strengthening processes of metals.
Grain-size reduction
Solid-solution alloying
Strain hardening (work hardening or cold working)
Annealing of deformed metals
The document discusses die casting, which is a permanent mold casting process where metal alloys such as aluminum, magnesium, and copper are poured into metal molds to produce a large number of identical castings. There are two main types of die casting: gravity die casting where molten metal is poured by hand into molds, and pressure die casting where molten metal is injected into molds under high pressure. Pressure die casting provides smoother, more dimensionally accurate castings and is used to manufacture small castings in industries.
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.
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.
The document provides an overview of metal forming processes. It discusses:
- Metal forming involves plastic deformation using tools like dies to change a metal's shape. This deformation exceeds the metal's yield strength.
- Processes include bulk deformation (rolling, forging, extrusion, drawing) and sheet metal working (bending, drawing, shearing).
- The flow curve describes a metal's plastic behavior during forming, showing how flow stress increases with strain hardening. Flow stress determines the forces needed for forming.
Bulk deformation processes involve significant shape changes and massive deformations of metal workpieces that have a low surface area to volume ratio, such as cylindrical billets and bars. The main bulk deformation processes are rolling, forging, extrusion, and drawing. Rolling involves reducing the thickness of metal between two rotating cylindrical rolls. Forging uses compression between dies to impart shapes to the workpiece. Extrusion forces metal to flow through a die opening to take its shape. Drawing reduces the diameter of wire or bar by pulling it through a die.
Extrusion, Drawing, Forging and Sheetmetal working processesmulualemamar
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).
Bulk deformation processes are metal forming operations that cause significant shape change through plastic deformation of initially bulk metal parts like bars, billets, and slabs. The main bulk deformation processes are rolling, forging, extrusion, and drawing.
Rolling reduces the thickness of metal by passing it through opposing rolls. Forging shapes metal by compressing it between dies under impact or gradual pressure. Extrusion forces metal through a die opening to take on its cross-sectional shape. Drawing reduces the diameter of wires or bars by pulling them through a die. These processes are commonly done hot to facilitate greater plastic deformation.
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.
Extrusion process presentation final (1).pptxAhmedWail2
The document discusses different types of extrusion processes including hot and cold extrusion, direct and indirect extrusion, and impact and hydrostatic extrusion. It explains the key factors that affect extrusion quality such as extrusion ratio, billet temperature, lubrication, and die design. Various extrusion products are also presented including tubes, hollow pipes, frames, and plastic objects.
The document discusses various bulk metal deformation processes including rolling, forging, extrusion, and drawing. It provides details on the mechanics and applications of these processes. Specifically, it describes techniques like flat rolling, shape rolling, thread rolling, open-die forging, impression-die forging, multi-step forging, flashless forging, upsetting and heading, rotary swaging, direct and indirect extrusion, hot and cold extrusion, and wire and bar drawing. Diagrams are included to illustrate key aspects of each technique.
The document discusses various metal forming processes including rolling, forging, and extrusion. It describes rolling as reducing thickness of metal between opposing rolls. The main types are flat rolling and shape rolling, with hot rolling being most common. Forging involves compressing metal between dies to shape it. The main types are cold forging, hot forging, drop forging, and press forging. Extrusion uses compression to force metal through a die opening to produce parts with uniform cross-sections like rods.
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.
This document discusses various metal forming processes including rolling, extrusion, forging, and drawing. It provides definitions and descriptions of each process. Rolling involves passing metal through rotating rolls to reduce thickness or shape it. Extrusion uses a press to force heated metal through a die to shape it. Forging shapes heated metal by compressing it with dies or hammers. Drawing shapes metal by pulling it through a die to reduce its cross-sectional area. Each process deforms metal through compression or tension to form parts.
Sheet metal working for non ferrous metal and alloysNikunj Patel
its sheet metal working for non ferrous metal and alloy. its show all process like punching, deep drawing, etc which can employ in sheet metal working.its show how process done in short details.
Metal forming processes use plastic deformation to change the shape of metal workpieces. Rolling is one of the most common metal forming processes, accounting for around 90% of metal shaping. In rolling, the metal workpiece is passed through one or more sets of rolls, reducing the thickness and changing the cross-sectional area under compressive forces applied by the rolls. The geometry of the final product is determined by the shape and contour of the roll gap. Rolling can be performed hot or cold, and is used to produce a wide variety of parts for structural applications and transportation.
This document provides an overview of the extrusion process. It defines extrusion as forcing a block of metal through a die under high pressure to reduce its cross-section. Extrusion can be hot or cold, direct or indirect. It discusses extrusion equipment, pressures, ratios, defects, and features like its cost-effectiveness and ability to produce complex cross-sections. Hydrostatic extrusion is also introduced, where the billet is surrounded by a fluid and forced through the die.
This document discusses forging and forging processes. It defines forging as the controlled plastic deformation of metals at elevated temperatures using compressive forces. Forging enhances mechanical properties like strength and toughness. Forgeability is the tolerance of a metal to deform without failure, and can be evaluated using hot twist, upset, and hot impact tests. Common forging materials include aluminium alloys, steels, and titanium alloys. Forging is classified as open die or close die, with close die allowing more complex shapes. Processes include drop forging, press forging, and machine forging. Forging improves properties like strength and reduces machining time.
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.
Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapte...University of Maribor
Slides from talk presenting:
Aleš Zamuda: Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapter and Networking.
Presentation at IcETRAN 2024 session:
"Inter-Society Networking Panel GRSS/MTT-S/CIS
Panel Session: Promoting Connection and Cooperation"
IEEE Slovenia GRSS
IEEE Serbia and Montenegro MTT-S
IEEE Slovenia CIS
11TH INTERNATIONAL CONFERENCE ON ELECTRICAL, ELECTRONIC AND COMPUTING ENGINEERING
3-6 June 2024, Niš, Serbia
Understanding Inductive Bias in Machine LearningSUTEJAS
This presentation explores the concept of inductive bias in machine learning. It explains how algorithms come with built-in assumptions and preferences that guide the learning process. You'll learn about the different types of inductive bias and how they can impact the performance and generalizability of machine learning models.
The presentation also covers the positive and negative aspects of inductive bias, along with strategies for mitigating potential drawbacks. We'll explore examples of how bias manifests in algorithms like neural networks and decision trees.
By understanding inductive bias, you can gain valuable insights into how machine learning models work and make informed decisions when building and deploying them.
Harnessing WebAssembly for Real-time Stateless Streaming PipelinesChristina Lin
Traditionally, dealing with real-time data pipelines has involved significant overhead, even for straightforward tasks like data transformation or masking. However, in this talk, we’ll venture into the dynamic realm of WebAssembly (WASM) and discover how it can revolutionize the creation of stateless streaming pipelines within a Kafka (Redpanda) broker. These pipelines are adept at managing low-latency, high-data-volume scenarios.
Embedded machine learning-based road conditions and driving behavior monitoringIJECEIAES
Car accident rates have increased in recent years, resulting in losses in human lives, properties, and other financial costs. An embedded machine learning-based system is developed to address this critical issue. The system can monitor road conditions, detect driving patterns, and identify aggressive driving behaviors. The system is based on neural networks trained on a comprehensive dataset of driving events, driving styles, and road conditions. The system effectively detects potential risks and helps mitigate the frequency and impact of accidents. The primary goal is to ensure the safety of drivers and vehicles. Collecting data involved gathering information on three key road events: normal street and normal drive, speed bumps, circular yellow speed bumps, and three aggressive driving actions: sudden start, sudden stop, and sudden entry. The gathered data is processed and analyzed using a machine learning system designed for limited power and memory devices. The developed system resulted in 91.9% accuracy, 93.6% precision, and 92% recall. The achieved inference time on an Arduino Nano 33 BLE Sense with a 32-bit CPU running at 64 MHz is 34 ms and requires 2.6 kB peak RAM and 139.9 kB program flash memory, making it suitable for resource-constrained embedded systems.
CHINA’S GEO-ECONOMIC OUTREACH IN CENTRAL ASIAN COUNTRIES AND FUTURE PROSPECTjpsjournal1
The rivalry between prominent international actors for dominance over Central Asia's hydrocarbon
reserves and the ancient silk trade route, along with China's diplomatic endeavours in the area, has been
referred to as the "New Great Game." This research centres on the power struggle, considering
geopolitical, geostrategic, and geoeconomic variables. Topics including trade, political hegemony, oil
politics, and conventional and nontraditional security are all explored and explained by the researcher.
Using Mackinder's Heartland, Spykman Rimland, and Hegemonic Stability theories, examines China's role
in Central Asia. This study adheres to the empirical epistemological method and has taken care of
objectivity. This study analyze primary and secondary research documents critically to elaborate role of
china’s geo economic outreach in central Asian countries and its future prospect. China is thriving in trade,
pipeline politics, and winning states, according to this study, thanks to important instruments like the
Shanghai Cooperation Organisation and the Belt and Road Economic Initiative. According to this study,
China is seeing significant success in commerce, pipeline politics, and gaining influence on other
governments. This success may be attributed to the effective utilisation of key tools such as the Shanghai
Cooperation Organisation and the Belt and Road Economic Initiative.
TIME DIVISION MULTIPLEXING TECHNIQUE FOR COMMUNICATION SYSTEMHODECEDSIET
Time Division Multiplexing (TDM) is a method of transmitting multiple signals over a single communication channel by dividing the signal into many segments, each having a very short duration of time. These time slots are then allocated to different data streams, allowing multiple signals to share the same transmission medium efficiently. TDM is widely used in telecommunications and data communication systems.
### How TDM Works
1. **Time Slots Allocation**: The core principle of TDM is to assign distinct time slots to each signal. During each time slot, the respective signal is transmitted, and then the process repeats cyclically. For example, if there are four signals to be transmitted, the TDM cycle will divide time into four slots, each assigned to one signal.
2. **Synchronization**: Synchronization is crucial in TDM systems to ensure that the signals are correctly aligned with their respective time slots. Both the transmitter and receiver must be synchronized to avoid any overlap or loss of data. This synchronization is typically maintained by a clock signal that ensures time slots are accurately aligned.
3. **Frame Structure**: TDM data is organized into frames, where each frame consists of a set of time slots. Each frame is repeated at regular intervals, ensuring continuous transmission of data streams. The frame structure helps in managing the data streams and maintaining the synchronization between the transmitter and receiver.
4. **Multiplexer and Demultiplexer**: At the transmitting end, a multiplexer combines multiple input signals into a single composite signal by assigning each signal to a specific time slot. At the receiving end, a demultiplexer separates the composite signal back into individual signals based on their respective time slots.
### Types of TDM
1. **Synchronous TDM**: In synchronous TDM, time slots are pre-assigned to each signal, regardless of whether the signal has data to transmit or not. This can lead to inefficiencies if some time slots remain empty due to the absence of data.
2. **Asynchronous TDM (or Statistical TDM)**: Asynchronous TDM addresses the inefficiencies of synchronous TDM by allocating time slots dynamically based on the presence of data. Time slots are assigned only when there is data to transmit, which optimizes the use of the communication channel.
### Applications of TDM
- **Telecommunications**: TDM is extensively used in telecommunication systems, such as in T1 and E1 lines, where multiple telephone calls are transmitted over a single line by assigning each call to a specific time slot.
- **Digital Audio and Video Broadcasting**: TDM is used in broadcasting systems to transmit multiple audio or video streams over a single channel, ensuring efficient use of bandwidth.
- **Computer Networks**: TDM is used in network protocols and systems to manage the transmission of data from multiple sources over a single network medium.
### Advantages of TDM
- **Efficient Use of Bandwidth**: TDM all
Comparative analysis between traditional aquaponics and reconstructed aquapon...bijceesjournal
The aquaponic system of planting is a method that does not require soil usage. It is a method that only needs water, fish, lava rocks (a substitute for soil), and plants. Aquaponic systems are sustainable and environmentally friendly. Its use not only helps to plant in small spaces but also helps reduce artificial chemical use and minimizes excess water use, as aquaponics consumes 90% less water than soil-based gardening. The study applied a descriptive and experimental design to assess and compare conventional and reconstructed aquaponic methods for reproducing tomatoes. The researchers created an observation checklist to determine the significant factors of the study. The study aims to determine the significant difference between traditional aquaponics and reconstructed aquaponics systems propagating tomatoes in terms of height, weight, girth, and number of fruits. The reconstructed aquaponics system’s higher growth yield results in a much more nourished crop than the traditional aquaponics system. It is superior in its number of fruits, height, weight, and girth measurement. Moreover, the reconstructed aquaponics system is proven to eliminate all the hindrances present in the traditional aquaponics system, which are overcrowding of fish, algae growth, pest problems, contaminated water, and dead fish.
KuberTENes Birthday Bash Guadalajara - K8sGPT first impressionsVictor Morales
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Redefining brain tumor segmentation: a cutting-edge convolutional neural netw...IJECEIAES
Medical image analysis has witnessed significant advancements with deep learning techniques. In the domain of brain tumor segmentation, the ability to
precisely delineate tumor boundaries from magnetic resonance imaging (MRI)
scans holds profound implications for diagnosis. This study presents an ensemble convolutional neural network (CNN) with transfer learning, integrating
the state-of-the-art Deeplabv3+ architecture with the ResNet18 backbone. The
model is rigorously trained and evaluated, exhibiting remarkable performance
metrics, including an impressive global accuracy of 99.286%, a high-class accuracy of 82.191%, a mean intersection over union (IoU) of 79.900%, a weighted
IoU of 98.620%, and a Boundary F1 (BF) score of 83.303%. Notably, a detailed comparative analysis with existing methods showcases the superiority of
our proposed model. These findings underscore the model’s competence in precise brain tumor localization, underscoring its potential to revolutionize medical
image analysis and enhance healthcare outcomes. This research paves the way
for future exploration and optimization of advanced CNN models in medical
imaging, emphasizing addressing false positives and resource efficiency.
1. Forging
Forging is a deformation process in which the work
is compressed between two dies, using either impact
or gradual pressure to form the part.
It is the oldest of the metal forming operations dating
back to perhaps 5000 BCE.
Today, forging is an important industrial process used
to make a variety of high-strength components for
automotive, aerospace, and other applications.
These components include engine crankshafts and
connecting rods, gears, aircraft structural components,
and jet engine turbine parts.
2. Classification of Forging
Forging is classified by working temperature.
Forging operations are performed hot or warm,
demanded by the process and the need to reduce
strength and increase ductility of the work metal.
However, cold forging is also very common for certain
products.
The advantage of cold forging is the increased
strength that results from strain hardening of the
component.
Forging hammers and presses used in operations.
3. Types of Forging
Open-die forging, work is compressed between two
flat dies, thus allowing the metal to flow without
constraint in a lateral direction relative to the die
surfaces.
Impression-die forging, die surfaces contain a
shape or impression that is imparted to the work
during compression, thus constraining metal flow to a
significant degree. In this type of operation, a portion
of the work metal flows beyond the die impression to
form flash (Flash is excess metal that must be
trimmed off later).
4. Flash less forging
Flash less forging, work is completely constrained
within die and no excess flash is produced.
The volume of starting work piece must be controlled
very closely so that it matches the volume of the die
cavity.
6. Open die Forging
Open-die forging involves compression of a work part of
cylindrical cross section between two flat dies, much in the
manner as compression test .
This forging operation, known as upsetting or upset
forging, reduces height of work and increases diameter.
Analysis of Open-Die Forging: Open-die forging is
carried out under ideal conditions no friction between
work and die surfaces, homogeneous deformation occurs,
and radial flow of the material is uniform throughout its
height.
Under these ideal conditions, the true strain experienced
by the work during the process can be determined by
8. Analysis of open die forging
where F = force, lb (N)
A= cross-sectional area of work mm2 (in2)
Yf = flow stress corresponding to the strain given by Eq.
MPa (lb/in2).
Area A continuously increases during the operation as
height is reduced.
Flow stress Yf also increases as a result of work hardening,
except when the metal is perfectly plastic ( hot working).
Strain-hardening exponent n = 0, and flow stress Yf
equals the metal’s yield strength Y.
Force reaches a maximum value at the end of the forging
stroke, when both area and flow stress are at their highest
values.
10. Analysis of open die Forging
In upset forging friction opposes the flow of work
metal at the die surfaces. This creates the barreling
effect , When performed on a hot work part with cold
dies, the barreling effect is even more pronounced.
This results from a higher coefficient of friction typical
in hot working and heat transfer at and near the die
surfaces, which cools the metal and increases its
resistance to deformation, hotter metal in the middle
of the part flows more readily than the cooler metal at
the ends. These effects are more significant as the
diameter-to-height ratio of work part increases, due
to greater contact area at work–die interface.
12. Analysis of open die Forging
we can apply a shape factor to account for effects of
the D/h ratio and friction:
F, Yf , and A have the same definitions as in the
previous equation; and Kf is the forging shape factor.
14. Open die forging practice
An example of open-die forging in the steel
industry is the shaping of a large square cast
ingot into a round cross section.
Open-die forging operations produce rough
forms, and subsequent operations are
required to refine the parts to final geometry
and dimensions.
An important contribution of open-die hot-
forging is that it creates a favorable grain flow
and metallurgical structure in the metal.
15. Classification of open die forging
Fullering is a forging operation performed to reduce
the cross section and redistribute the metal in a
work part in preparation for subsequent shape
forging.
It is accomplished by dies with convex surfaces.
Fullering die cavities are often designed into multi-
cavity impression dies, so that the starting bar can
be rough formed before final shaping.
Edging is similar to fullering, except that the dies
have concave surfaces.
16. Classification of open die forging
Cogging operation consists of a sequence of
forging compressions along the length of a
work piece to reduce cross section and
increase length.
It is used in the steel industry to produce
blooms and slabs from cast ingots.
It is accomplished using open dies with flat
or slightly contoured surfaces. The term
incremental forging is sometimes used for
this process
18. Impression- die Forging
Impression-die forging: sometimes called closed-die
forging, is performed with dies that contain inverse of
desired shape of the part.
Work piece is a cylindrical part similar to that used in the
previous open-die operation.
As the die closes to its final position, flash is formed by metal
that flows beyond die cavity and into small gap between die
plates.
Although this flash must be cut away from the part in a
subsequent trimming operation.
As flash begins to form in die gap, friction resists continued
flow of metal into the gap, thus constraining bulk of the work
material to remain in the die cavity.
19. Impression- die forging
In hot forging, metal flow is further restricted
because the thin flash cools quickly against the die
plates, thereby increasing its resistance to
deformation.
Restricting metal flow in the gap causes the
compression pressures on the part to increase
significantly, thus forcing the material to fill the die
cavity
The force formula is the same as previous Eq. open-
die forging, but its interpretation is slightly different.
22. Impression- die forging
Impression-die forging is not capable of close
tolerance and machining is often required.
The basic geometry of the part is obtained from the
forging process, with machining performed on those
portions of the part that require precision finishing
(e.g., holes, threads, and surfaces that mate with other
components).
The advantages of impression die forging , higher
production rates , greater strength, and favorable
grain orientation .
23. Impression die Forging
Improvements in the technology of impression-die
forging have resulted in the capability to produce
forgings with thinner sections, more complex
geometries, drastic reductions in draft requirements
on the dies, closer tolerances, and the virtual
elimination of machining allowances. Forging
processes with these features are known as precision
forging. Common work metals used for precision
forging include aluminum and titanium.
impression-die forging .
24. Flash less Forging
In flash less forging raw work piece is completely
contained within the die cavity during compression,
and no flash is formed.
Work volume must equal the space in die cavity
within a very close tolerance. If the starting blank is
too large, excessive pressures may cause damage to
die or press. If blank is too small, the cavity will not be
filled.
The parts geometries that are usually simple and
symmetrical, and to work materials such as aluminum
and magnesium and their alloys.
26. Flash less forging
Forces in flash less forging computed using the same
methods as for impression-die forging.
27. Forging hammers
Equipment used in forging consists of forging
machines, classified as hammers or presses, and
forging dies, which are the special tooling used in
these machines.
In addition, furnaces to heat the work, mechanical
devices to load and unload the work, and trimming
stations to cut away the flash in impression-die
forging.
Forging hammers operate by applying an impact
loading against work. The term drop hammer is often
used for these machines, owing to the means of
delivering impact energy.
30. Forging hammers
Upper portion of forging die is attached to ram, and
lower portion is attached to the anvil.
In operation, work is placed on the lower die, and the ram
is lifted and then dropped. When the upper die strikes the
work, the impact energy causes the part to assume the
form of the die cavity.
Several blows of hammer are often required to achieve
the desired shape.
Drop hammers can be classified as gravity drop hammers
and power drop hammers. Gravity drop hammers achieve
their energy by the falling weight of a heavy ram. The force
of the blow is determined by the height of the drop and the
weight of the ram.
Power drop hammers accelerate the ram by pressurized
air or steam.
31. Disadvantages
Drop hammer for
impression die forging
Disadvantages of drop
hammers is that a large
amount of the impact
energy is transmitted
through the anvil and
into the floor of the
building.
Forging hammers
32. Forging Presses
Forging Presses: apply gradual pressure, rather
than sudden impact to accomplish the forging
operation.
Forging presses include mechanical presses,
hydraulic presses, and screw presses.
Mechanical presses: operate by means of
eccentrics, cranks, or knuckle joints, which convert
the rotating motion of a drive motor into the
translation motion of the ram. These mechanisms are
very similar to those used in stamping presses .
33. Forging Presses
Hydraulic presses use a hydraulically driven
piston to activate the ram.
Screw presses apply force by a screw mechanism
that drives the vertical ram. Both screw drive and
hydraulic drive operate at relatively low ram speeds
and can provide a constant force throughout the
stroke.
These machines are therefore suitable for forging
(and other forming) operations that require a long
stroke.
34. Forging dies
Forging Dies Parts to be forged must be designed
based on knowledge of the principles and limitations
of this process. Design of open dies is generally
straight forward because the dies are relatively simple
in shape.
Parting line. The parting line is the plane that
divides the upper die from the lower die called the
flash line in impression-die forging, it is the plane
where the two die halves meet. Its selection by the
designer affects grain flow in the part, required load,
and flash formation.
36. Draft Web and Ribs
Draft is the amount of taper on the sides of the part
required to remove it from the die. The term also
applies to the taper on the sides of the die cavity.
Typical draft angles are 3 on aluminum and
magnesium parts and 5 to 7 on steel parts. Draft
angles on precision forgings are near zero.
Webs and ribs. A web is a thin portion of the
forging that is parallel to the parting line, while a rib
is a thin portion that is perpendicular to the parting
line. These part features cause difficulty in metal
flow as they become thinner.