The document discusses various metal forming processes, specifically focusing on forging and rolling. It defines forming, cold working, warm working and hot working based on the temperature of deformation relative to the material's melting point. The key forming processes covered are forging (smith forging, drop forging, press forging, machine forging), rolling (functions, types of mills, drafting), and extrusion (forward and backward extrusion, uses). Diagrams illustrate examples and defects are also outlined for each process.
This document provides an overview of sheet metal forming processes. It discusses both cutting (shearing) operations like punching, blanking, and notching as well as forming operations like bending, drawing, squeezing, and hydroforming. The document describes various bending operations including V-bending, roll bending, and tube bending. It also discusses processes for forming parts like deep drawing, ironing, redrawing, and the multi-step metal forming process used to produce aluminum beverage cans.
Flexible tooling in metal forming uses a male or female die along with a flexible pad, typically made of polyurethane or rubber, to reduce costs and time compared to conventional dies. With flexible tooling, when manufacturing different product shapes, dies can be easily interchanged without alignment issues and the same flexible pad can form multiple workpiece shapes. Some key flexible forming techniques include multi-point press forming, multi-point stretch forming, and digitally flexible multi-point tooling. Flexible tooling provides advantages like reduced costs, improved quality, and adaptability to CAD/CAM operations.
Sheet metal is a thin piece of metal between 0.006 and 0.25 inches thick. Sheet metal can be cut, bent, and stretched into various shapes through forming and cutting operations. Common forming operations include bending, deep drawing, and roll forming. Common cutting operations include shearing, blanking, punching, notching, and slitting. Sheet metal workers use tools like dies and presses to perform these operations and shape the metal.
This document provides an overview of various sheet metal forming processes. It begins with an introduction to shearing, which involves applying shear stress between a punch and die to cut sheet metal. Key shearing operations like punching, blanking, and progressive dies are described. Other forming methods discussed include bending, deep drawing, stretch forming, spinning, explosive forming, and super plastic forming. Process parameters, equipment, advantages, limitations, and examples of parts made for each technique are summarized. The document provides a comprehensive reference on the different ways sheet metal can be shaped and fabricated.
Sheet metal forming processes like blanking, bending, and deep drawing are used to manufacture automotive and other stamped metal parts. Progressive dies can produce parts quickly by performing multiple stamping operations simultaneously as the sheet metal passes through the die stations. Transfer lines also enable high-volume production by transferring pre-formed sheet metal components between successive presses using transfer dies.
This document describes procedures for conducting a deep drawing test to determine the ductility of sheet metal. The test involves clamping a sheet metal sample at its edges and forcing a conical or hemispherical punch into the sample to form a cup shape. The depth the punch can form before fracture occurs is measured to assess the sample's ductility. The test determines whether a material is suitable for deep drawing processes which shape sheet metal through tensile stretching and compressive forces without cracking.
Deep drawing is a metal forming process where a sheet metal blank is placed over a die opening and forced into the die cavity by a punch. It is commonly used to make cylindrical or box-shaped parts like pots, pans, and automotive fuel tanks. Metals used include alloys, aluminum, brass, cold rolled steel, and copper. Lubrication is applied to reduce forces and increase formability.
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.
This document provides an overview of sheet metal forming processes. It discusses both cutting (shearing) operations like punching, blanking, and notching as well as forming operations like bending, drawing, squeezing, and hydroforming. The document describes various bending operations including V-bending, roll bending, and tube bending. It also discusses processes for forming parts like deep drawing, ironing, redrawing, and the multi-step metal forming process used to produce aluminum beverage cans.
Flexible tooling in metal forming uses a male or female die along with a flexible pad, typically made of polyurethane or rubber, to reduce costs and time compared to conventional dies. With flexible tooling, when manufacturing different product shapes, dies can be easily interchanged without alignment issues and the same flexible pad can form multiple workpiece shapes. Some key flexible forming techniques include multi-point press forming, multi-point stretch forming, and digitally flexible multi-point tooling. Flexible tooling provides advantages like reduced costs, improved quality, and adaptability to CAD/CAM operations.
Sheet metal is a thin piece of metal between 0.006 and 0.25 inches thick. Sheet metal can be cut, bent, and stretched into various shapes through forming and cutting operations. Common forming operations include bending, deep drawing, and roll forming. Common cutting operations include shearing, blanking, punching, notching, and slitting. Sheet metal workers use tools like dies and presses to perform these operations and shape the metal.
This document provides an overview of various sheet metal forming processes. It begins with an introduction to shearing, which involves applying shear stress between a punch and die to cut sheet metal. Key shearing operations like punching, blanking, and progressive dies are described. Other forming methods discussed include bending, deep drawing, stretch forming, spinning, explosive forming, and super plastic forming. Process parameters, equipment, advantages, limitations, and examples of parts made for each technique are summarized. The document provides a comprehensive reference on the different ways sheet metal can be shaped and fabricated.
Sheet metal forming processes like blanking, bending, and deep drawing are used to manufacture automotive and other stamped metal parts. Progressive dies can produce parts quickly by performing multiple stamping operations simultaneously as the sheet metal passes through the die stations. Transfer lines also enable high-volume production by transferring pre-formed sheet metal components between successive presses using transfer dies.
This document describes procedures for conducting a deep drawing test to determine the ductility of sheet metal. The test involves clamping a sheet metal sample at its edges and forcing a conical or hemispherical punch into the sample to form a cup shape. The depth the punch can form before fracture occurs is measured to assess the sample's ductility. The test determines whether a material is suitable for deep drawing processes which shape sheet metal through tensile stretching and compressive forces without cracking.
Deep drawing is a metal forming process where a sheet metal blank is placed over a die opening and forced into the die cavity by a punch. It is commonly used to make cylindrical or box-shaped parts like pots, pans, and automotive fuel tanks. Metals used include alloys, aluminum, brass, cold rolled steel, and copper. Lubrication is applied to reduce forces and increase formability.
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.
This document discusses sheet metal forming processes. Sheet metal forming takes a flat sheet of metal and uses mechanical forces to alter its shape. There are two main categories of sheet metal operations on a press: shearing/cutting operations and forming operations. Shearing operations like punching, blanking, and notching stress the metal beyond its strength limit. Forming operations like bending, drawing, spinning, and flanging mechanically deform the metal into the desired shape without breaking it. An example given is the process used to form aluminum cans.
This document discusses deep drawing, a sheet metal forming process where a punch is used to push a flat sheet into a die cavity. It describes the typical tool setup, components made via deep drawing like cups and conical shapes, and calculations for blank diameter. Stress patterns in different regions during drawing are explained. Factors affecting drawability and defects in formed components like wrinkling and bottom fracture are also summarized. Formulas for total punch force and drawability ratio are provided. Methods to improve drawability like redrawing and controlling texture are outlined.
This document discusses sheet metal working processes. It begins by explaining that sheet metal forming dates back thousands of years and is used to make a wide variety of consumer and industrial products. The main sheet metal forming processes are stretching, bending, deep drawing, and press working. Press working shapes sheet metal using dies and punches without removing material. The document then goes into details about various sheet metal forming operations, tools, and calculations for processes like bending, deep drawing, blanking, and punching.
Okay, here are the steps:
1) UTS of 5052-O aluminum = 280 MPa
2) Thickness, t = 1.8 mm
3) Cutting edge length, L = πD = π * 25 mm = 78.5 mm
4) Using the empirical formula:
Fmax = 7.0 * UTS * t * L
= 7.0 * 280 * 1.8 * 78.5
= 3,400 N
So the estimated maximum punch force required is 3,400 Newtons.
Sheet metal forming is a versatile manufacturing process used to produce lightweight parts with complex shapes. Common forming operations include punching, blanking, bending, deep drawing, and stamping. Key considerations in sheet metal forming include the material properties, forming limits, stresses induced during forming, and techniques to reduce waste and improve dimensional accuracy. Proper tool and die design is critical for successful forming of sheet metal parts.
This document discusses various forming operations used in sheet metal working. It describes processes like bending, coining, embossing, flanging, hole flanging, beading and curling, ironing, and drawing. For each process, it provides details on how the process works, common applications, advantages and disadvantages. It also discusses considerations for forming die design like part material properties, number of required stampings, and clearance between the punch and die.
Sheet metal fabrication involves shaping metal sheets through forming or cutting processes. Forming bends or stretches the sheet without removing material, while cutting separates material. Common forming methods include bending, roll forming, spinning, and deep drawing, which shape the sheet. Sheet metal can be cut using shearing, punching, laser cutting, or plasma cutting. Final parts are used in industries like construction, appliances, furniture, and automobiles.
This document summarizes sheet metal forming processes like shearing, punching, bending, and deep drawing. It discusses the basic techniques, important parameters, and applications for each process. Key points include that low-carbon steel is commonly used for its strength and formability. Shearing involves cutting a blank from a sheet using a punch and die. Minimum bend radius depends on the sheet thickness and material properties to prevent cracking. Deep drawing is used to form containers and other cylindrical or box-shaped parts, with formability determined by the limiting drawing ratio.
This document discusses various sheet metal forming processes including cutting, bending, drawing and other operations. It defines sheet metalworking as including cutting and forming thin sheets of metal between 0.4mm to 6mm thick. Common sheet metal forming processes are described as shearing, blanking, punching, bending and drawing. Factors involved in sheet metal cutting like clearance, punch and die sizes, and estimating cutting forces are also summarized.
Sheet metal operations are cold-working processes that can manufacture low-cost metal parts in high volumes quickly. Sheet metal is metal between 0.006-0.25 inches thick that can be cut, bent, or stretched into various shapes. Common sheet metal operations include embossing to add raised or sunken designs using heat and pressure, coining to add similar impressions to both sides, spinning to shape metal over a rotating mandrel, stretch forming to simultaneously stretch and bend metal over a die, and nibbling which cuts contoured shapes using overlapping slits.
This document discusses various sheet metal forming processes. It describes cutting processes like shearing, blanking, and punching. It also describes bending, drawing, embossing, stretch forming, roll forming, and spinning. Sheet metal is commonly used to make parts for vehicles, appliances, furniture and more. Cutting is done using punches and dies in presses or shears. Proper clearance and tool sizes are important. Bending involves straining metal around an axis. Drawing forms complex curved shapes using punches and dies.
Sheet metal processes involve cutting, bending, and drawing operations. Shearing is the primary cutting operation used to cut sheet metal blanks from large sheets. It involves using a punch and die to cut along a straight line. Bending forms sheet metal by curving it around a straight axis and is done using V-bending or edge bending. Both cutting and bending can result in springback as the sheet tries to return to its original shape after forming. Process parameters like punch and die design, clearance, and lubrication affect the quality of cuts and bends in sheet metal fabrication.
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.
The document discusses various fundamentals of metal forming processes including hot working, cold working, and warm working operations. It describes different metal forming techniques like forging, rolling, extrusion, and describes tools used in smithy like anvil, hammers, swages, and forging operations like upsetting, drawing, bending, and punching.
Ch6 sheetmetw proc (1) Erdi Karaçal Mechanical Engineer University of GaziantepErdi Karaçal
The document discusses sheet metal working processes and cutting operations. It describes the three major categories of sheet metal processes as cutting, bending, and drawing. Cutting operations like shearing, blanking, and piercing are used to separate sheet metal into pieces or make holes. Proper die clearances and cutting forces must be considered for optimal cutting. Tools called punches and dies are used to perform these operations on stamping presses.
The document discusses various sheet metalworking processes including cutting, bending, and drawing. Cutting operations like shearing, blanking, and punching are used to cut sheet metal. Bending involves straining sheet metal around a straight axis using methods like V-bending and edge bending. Drawing forms sheet metal into convex or concave shapes. Key considerations in sheet metalworking are clearance, bending allowances, springback, and forces required for cutting.
This document discusses various sheet metal processing techniques. Sheet metal can be cut and bent into different shapes from thin, flat metal pieces. Common sheet metal operations include cutting through techniques like shearing, blanking, punching, notching, perforating, slitting, and lancing. Forming techniques shape the metal and include bending, roll forming, spinning, deep drawing, and stretch forming. Each technique is described in one or two sentences with examples provided for some methods.
This document provides an overview of sheet metal forming processes. It discusses shearing processes like punching and blanking. It describes the effects of clearance between the punch and die on shearing. It also covers other processes like bending, bead forming, flanging, roll forming, and stretch forming. Various press types and die configurations used in sheet metal forming are also summarized.
sheet metal work ,die and punch.
it is generally useful for sheet metal operation.terminology of die and punch, types of die,types of punch,cutting force,method of reducing cutting force
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.
Makalah ini membahas tentang penarikan kawat, batang, dan tabung. Penjelasan mencakup definisi dan jenis-jenis penarikan logam seperti wire drawing, bar drawing, dan tube drawing. Selain itu diuraikan pula prinsip kerja, komponen gaya, dan faktor-faktor yang mempengaruhi hasil penarikan seperti reduksi, temperatur, dan delta factor."
This document provides an overview of geometric dimensioning and tolerancing (GD&T). It defines GD&T as a system for defining and communicating engineering tolerances using a symbolic language on drawings. It compares GD&T standards from ISO and ASME, describing differences in their approaches. The document also outlines the structure of the ASME Y14.5M-2009 standard and provides explanations and examples of common GD&T concepts like geometric characteristic symbols, flatness, circularity, position tolerance, and more.
This document discusses sheet metal forming processes. Sheet metal forming takes a flat sheet of metal and uses mechanical forces to alter its shape. There are two main categories of sheet metal operations on a press: shearing/cutting operations and forming operations. Shearing operations like punching, blanking, and notching stress the metal beyond its strength limit. Forming operations like bending, drawing, spinning, and flanging mechanically deform the metal into the desired shape without breaking it. An example given is the process used to form aluminum cans.
This document discusses deep drawing, a sheet metal forming process where a punch is used to push a flat sheet into a die cavity. It describes the typical tool setup, components made via deep drawing like cups and conical shapes, and calculations for blank diameter. Stress patterns in different regions during drawing are explained. Factors affecting drawability and defects in formed components like wrinkling and bottom fracture are also summarized. Formulas for total punch force and drawability ratio are provided. Methods to improve drawability like redrawing and controlling texture are outlined.
This document discusses sheet metal working processes. It begins by explaining that sheet metal forming dates back thousands of years and is used to make a wide variety of consumer and industrial products. The main sheet metal forming processes are stretching, bending, deep drawing, and press working. Press working shapes sheet metal using dies and punches without removing material. The document then goes into details about various sheet metal forming operations, tools, and calculations for processes like bending, deep drawing, blanking, and punching.
Okay, here are the steps:
1) UTS of 5052-O aluminum = 280 MPa
2) Thickness, t = 1.8 mm
3) Cutting edge length, L = πD = π * 25 mm = 78.5 mm
4) Using the empirical formula:
Fmax = 7.0 * UTS * t * L
= 7.0 * 280 * 1.8 * 78.5
= 3,400 N
So the estimated maximum punch force required is 3,400 Newtons.
Sheet metal forming is a versatile manufacturing process used to produce lightweight parts with complex shapes. Common forming operations include punching, blanking, bending, deep drawing, and stamping. Key considerations in sheet metal forming include the material properties, forming limits, stresses induced during forming, and techniques to reduce waste and improve dimensional accuracy. Proper tool and die design is critical for successful forming of sheet metal parts.
This document discusses various forming operations used in sheet metal working. It describes processes like bending, coining, embossing, flanging, hole flanging, beading and curling, ironing, and drawing. For each process, it provides details on how the process works, common applications, advantages and disadvantages. It also discusses considerations for forming die design like part material properties, number of required stampings, and clearance between the punch and die.
Sheet metal fabrication involves shaping metal sheets through forming or cutting processes. Forming bends or stretches the sheet without removing material, while cutting separates material. Common forming methods include bending, roll forming, spinning, and deep drawing, which shape the sheet. Sheet metal can be cut using shearing, punching, laser cutting, or plasma cutting. Final parts are used in industries like construction, appliances, furniture, and automobiles.
This document summarizes sheet metal forming processes like shearing, punching, bending, and deep drawing. It discusses the basic techniques, important parameters, and applications for each process. Key points include that low-carbon steel is commonly used for its strength and formability. Shearing involves cutting a blank from a sheet using a punch and die. Minimum bend radius depends on the sheet thickness and material properties to prevent cracking. Deep drawing is used to form containers and other cylindrical or box-shaped parts, with formability determined by the limiting drawing ratio.
This document discusses various sheet metal forming processes including cutting, bending, drawing and other operations. It defines sheet metalworking as including cutting and forming thin sheets of metal between 0.4mm to 6mm thick. Common sheet metal forming processes are described as shearing, blanking, punching, bending and drawing. Factors involved in sheet metal cutting like clearance, punch and die sizes, and estimating cutting forces are also summarized.
Sheet metal operations are cold-working processes that can manufacture low-cost metal parts in high volumes quickly. Sheet metal is metal between 0.006-0.25 inches thick that can be cut, bent, or stretched into various shapes. Common sheet metal operations include embossing to add raised or sunken designs using heat and pressure, coining to add similar impressions to both sides, spinning to shape metal over a rotating mandrel, stretch forming to simultaneously stretch and bend metal over a die, and nibbling which cuts contoured shapes using overlapping slits.
This document discusses various sheet metal forming processes. It describes cutting processes like shearing, blanking, and punching. It also describes bending, drawing, embossing, stretch forming, roll forming, and spinning. Sheet metal is commonly used to make parts for vehicles, appliances, furniture and more. Cutting is done using punches and dies in presses or shears. Proper clearance and tool sizes are important. Bending involves straining metal around an axis. Drawing forms complex curved shapes using punches and dies.
Sheet metal processes involve cutting, bending, and drawing operations. Shearing is the primary cutting operation used to cut sheet metal blanks from large sheets. It involves using a punch and die to cut along a straight line. Bending forms sheet metal by curving it around a straight axis and is done using V-bending or edge bending. Both cutting and bending can result in springback as the sheet tries to return to its original shape after forming. Process parameters like punch and die design, clearance, and lubrication affect the quality of cuts and bends in sheet metal fabrication.
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.
The document discusses various fundamentals of metal forming processes including hot working, cold working, and warm working operations. It describes different metal forming techniques like forging, rolling, extrusion, and describes tools used in smithy like anvil, hammers, swages, and forging operations like upsetting, drawing, bending, and punching.
Ch6 sheetmetw proc (1) Erdi Karaçal Mechanical Engineer University of GaziantepErdi Karaçal
The document discusses sheet metal working processes and cutting operations. It describes the three major categories of sheet metal processes as cutting, bending, and drawing. Cutting operations like shearing, blanking, and piercing are used to separate sheet metal into pieces or make holes. Proper die clearances and cutting forces must be considered for optimal cutting. Tools called punches and dies are used to perform these operations on stamping presses.
The document discusses various sheet metalworking processes including cutting, bending, and drawing. Cutting operations like shearing, blanking, and punching are used to cut sheet metal. Bending involves straining sheet metal around a straight axis using methods like V-bending and edge bending. Drawing forms sheet metal into convex or concave shapes. Key considerations in sheet metalworking are clearance, bending allowances, springback, and forces required for cutting.
This document discusses various sheet metal processing techniques. Sheet metal can be cut and bent into different shapes from thin, flat metal pieces. Common sheet metal operations include cutting through techniques like shearing, blanking, punching, notching, perforating, slitting, and lancing. Forming techniques shape the metal and include bending, roll forming, spinning, deep drawing, and stretch forming. Each technique is described in one or two sentences with examples provided for some methods.
This document provides an overview of sheet metal forming processes. It discusses shearing processes like punching and blanking. It describes the effects of clearance between the punch and die on shearing. It also covers other processes like bending, bead forming, flanging, roll forming, and stretch forming. Various press types and die configurations used in sheet metal forming are also summarized.
sheet metal work ,die and punch.
it is generally useful for sheet metal operation.terminology of die and punch, types of die,types of punch,cutting force,method of reducing cutting force
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.
Makalah ini membahas tentang penarikan kawat, batang, dan tabung. Penjelasan mencakup definisi dan jenis-jenis penarikan logam seperti wire drawing, bar drawing, dan tube drawing. Selain itu diuraikan pula prinsip kerja, komponen gaya, dan faktor-faktor yang mempengaruhi hasil penarikan seperti reduksi, temperatur, dan delta factor."
This document provides an overview of geometric dimensioning and tolerancing (GD&T). It defines GD&T as a system for defining and communicating engineering tolerances using a symbolic language on drawings. It compares GD&T standards from ISO and ASME, describing differences in their approaches. The document also outlines the structure of the ASME Y14.5M-2009 standard and provides explanations and examples of common GD&T concepts like geometric characteristic symbols, flatness, circularity, position tolerance, and more.
Proses pembentukan logam meliputi pengerjaan panas dan dingin. Pengerjaan panas memiliki permukaan buruk tetapi logam tetap lunak, sedangkan pengerjaan dingin memiliki permukaan baik namun memerlukan gaya besar. Jenis-jenis proses pembentukan logam antara lain pengerolan, tempa, penekukan, penarikan, pembengkokan, pembentukan pipa, dan pelebungan tembus.
GD&T for Omega Fabrication, Melaka.4-5th March 2017Timothy Wooi
GD&T Course Objective
Provide Participants with Fundamental concepts of GD&T to express, understand and interpret drawing requirements using GD&T to ASME Y14.5 Standards.
To allow Participants to master techniques of GD&T in the ASME standard to;
integrate smoothly into engineering design applications and modern inspection systems at work.
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.
The document discusses project quality management. It covers quality theories, the evolution of quality management, and the three key quality management processes - plan quality management, perform quality assurance, and control quality.
Plan quality management involves identifying quality requirements and documenting how the project will demonstrate compliance. Perform quality assurance involves auditing quality requirements and results to ensure appropriate standards. Control quality involves monitoring and recording quality activities to assess performance and recommend changes.
dari materi tersebut menjelaskan bagaimana proses dari pembentukan logam, dimana proses tersebut membutuhkan waktu dan ketelitian yang tinggi untuk menghasilkan suatu produk yang berkualitas
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.
The document discusses 7 quality control tools used to identify, analyze, and resolve problems in a systematic manner. The tools include check sheets, histograms, Pareto charts, cause-and-effect diagrams, scatter plots, defect concentration diagrams, and control charts. These simple but powerful tools can help solve day-to-day work problems and identify solutions by collecting and analyzing process data.
The document provides an overview of 7 quality control tools: Pareto diagram, stratification, scatter diagram, cause and effect diagram, histogram, check sheet, and control chart/graph. It describes each tool, including what they are, when they are used, and the typical results obtained from each tool. The tools are used to collect and analyze data, identify root causes, measure results, and help solve problems in quality control.
This chapter discusses various metal extrusion processes. It begins by defining extrusion as forcing a metal billet through a die to reduce its cross-section. Various types of extrusion processes are classified, including direct/indirect extrusion and hot/cold extrusion. Equipment for extrusion like presses and dies are also described. Examples of products made by extrusion and specific processes like tube extrusion are provided. The chapter aims to provide useful background on extrusion processes and their analysis.
Forging is a metal forming process that uses compressive forces and hammer or die blows to shape metal. It is widely used in manufacturing industries like automotive and aerospace. Parts made by forging are stronger than those made by other metalworking processes like casting. This makes forgings suitable for applications requiring reliability and safety. Forging can produce parts in various shapes and is cost-effective for high production rates. However, it has disadvantages like oxidation causing scaling issues and high initial and maintenance costs for dies.
The document discusses various metal forming processes including rolling, extrusion, and forging. It describes rolling as reducing the cross-sectional area of metal by passing it through a pair of rotating rolls. Extrusion shapes metal by forcing a billet through a die opening, and can be direct or indirect. The document provides detailed information on rolling processes like flat rolling, shape rolling, thread rolling, and ring rolling, and the various types of rolling mills used.
This document provides an overview of bulk forming processes with a focus on rolling and forging. It begins by introducing bulk forming processes and classifying them as primary or secondary, bulk deformation or sheet forming, and hot or cold working. The main bulk deformation processes of rolling, forging, extrusion, and drawing are described. Rolling is discussed in depth, covering the basic rolling process, types of rolling mills, defects, and quality of rolled products. Forging techniques like open-die, impression die, press and roll forging are introduced. Upset forging rules and automatic hot forging are also summarized.
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 provides an overview of various metal forming processes taught in a Manufacturing Technology II course. It discusses processes like rolling, forging, extrusion, drawing, bending, and high-energy rate forming. For each process, it describes the basic mechanics, advantages, disadvantages, applications, and defects. It also defines key terms like hot working, cold working, and gives examples of specific processes like wire drawing, tube drawing, and thread rolling. Overall, the document serves as teaching material covering essential information on different metal forming techniques.
Forming Technology
Forging: Hot working, cold working – advantages of hot working
and cold working– hot working operations – rolling, forging, smith
forging, drop forging, upset forging, press forging – roll forging.
Press Working: Types of presses - mechanical and hydraulic
presses - press tools and accessories - press working operations -
bending operations - angle bending - channel bending – curling –
drawing - shearing operations - blanking, piercing, trimming –
notching – lancing.
This document provides information about Federal Mogul Bearing India Ltd., including:
1. Federal Mogul Bearing India Ltd. was established in 1979 and set up an engine bearing division in collaboration with Federal Mogul Corporation, USA to manufacture thin-wall engine bearings.
2. The company's mission is to provide superior products on time to delight customers and provide better than market returns to delight shareholders.
3. The quality policy commits to meeting or exceeding customer requirements by maintaining a quality management system focused on customer satisfaction, continual improvement, and safety.
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.
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.
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.
The document discusses various metal forming techniques including open-die forging, impression-die forging, and flashless forging. It describes how each process works and provides examples of parts made using forging. Defects that can occur during forging like unfilled sections, cold shuts, and scale pits are also reviewed. Different types of forging machines like drop hammers and presses are introduced.
RICO is an engineering group that supplies precision machined aluminum and ferrous components to automotive OEMs globally. It has several joint venture companies producing items like clutch assemblies, brake products, and pumps. RICO has multiple facilities across India that do casting, machining, assembly, and R&D. The Dharuhera facility produces over 16 million die cast components annually for customers like Hero Moto and Maruti Suzuki. It uses electric arc furnaces, high pressure die casting machines, and machining centers to produce parts. Quality is ensured through various checks and the production process follows 5S methodology.
Tooling, Testing and Processing of polymeric materials,describe about machines tooling, how's processing unit working and testing of polymeric materials.....
Sizing is a metalworking process performed below melting point to improve dimensional accuracy and surface finish of a workpiece. It involves applying pressure to minimize thickness and densify the metal's surface. Sizing is usually done on semi-finished or precision parts using an open die and produces parts with better dimensions and stronger surfaces.
The document describes the manufacturing processes used to produce key engine components. Engine blocks are typically made of cast aluminum alloys using a casting process. Pistons are commonly forged from aluminum alloys and undergo machining like cutting, drilling, and milling. Crankshafts are usually made from steel alloys using casting and machining processes like turning, drilling, and grinding. Gears are manufactured through gear forming methods like milling and broaching or gear generation processes like hobbing and shaping.
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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.
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Optimizing Gradle Builds - Gradle DPE Tour Berlin 2024Sinan KOZAK
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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.
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ACEP Magazine edition 4th launched on 05.06.2024Rahul
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The smart irrigation system represents an innovative approach to optimize water usage in agricultural and landscaping practices. The integration of cutting-edge technologies, including sensors, actuators, and data analysis, empowers this system to provide accurate monitoring and control of irrigation processes by leveraging real-time environmental conditions. The main objective of a smart irrigation system is to optimize water efficiency, minimize expenses, and foster the adoption of sustainable water management methods. This paper conducts a systematic risk assessment by exploring the key components/assets and their functionalities in the smart irrigation system. The crucial role of sensors in gathering data on soil moisture, weather patterns, and plant well-being is emphasized in this system. These sensors enable intelligent decision-making in irrigation scheduling and water distribution, leading to enhanced water efficiency and sustainable water management practices. Actuators enable automated control of irrigation devices, ensuring precise and targeted water delivery to plants. Additionally, the paper addresses the potential threat and vulnerabilities associated with smart irrigation systems. It discusses limitations of the system, such as power constraints and computational capabilities, and calculates the potential security risks. The paper suggests possible risk treatment methods for effective secure system operation. In conclusion, the paper emphasizes the significant benefits of implementing smart irrigation systems, including improved water conservation, increased crop yield, and reduced environmental impact. Additionally, based on the security analysis conducted, the paper recommends the implementation of countermeasures and security approaches to address vulnerabilities and ensure the integrity and reliability of the system. By incorporating these measures, smart irrigation technology can revolutionize water management practices in agriculture, promoting sustainability, resource efficiency, and safeguarding against potential security threats.
A SYSTEMATIC RISK ASSESSMENT APPROACH FOR SECURING THE SMART IRRIGATION SYSTEMS
Forming1
1. MI-102: Manufacturing Techniques I. I. T. ROORKEE
FORMING PROCESSES
Forming is a deformation based approach used to give the
desired size and shape.
Therefore, all factors affecting the deformation tendency
(ductility, yield strength, strain hardening) will eventually affect
the performance of the forming processes.
In General an increase in the Temperature results in
Decrease in Strength
Increase in Ductility
Decrease in the Rate of Strain Hardening
All these effects ease of deformation required for forming
On the basis of forming Temperature forming processes
can classified as
COLD Forming
WARM Forming
HOT Forming
2. MI-102: Manufacturing Techniques I. I. T. ROORKEE
COLD FORMING HOT FORMING
Below their Recrystallization
Temperature
Above their Recrystallization
Temperature
Temperature of Deformation <
0. 3 Melting Temperature on
the Absolute Scale
Temperature of Deformation
> 0.6 Melting Temperature on
the Absolute Scale
Recrystallization Temperature
Varies Greatly with the
Material
Tin is Near Hot-Working at
Room Temperature while Steel
Require Temp. near 1100o
C
WARM FORMING: Deformation Between 0.3 to 0.6 Times the
Melting Point on the Absolute Scale
3. MI-102: Manufacturing Techniques I. I. T. ROORKEE
Hot Working Cold Working
Processes
Forging
Rolling
Extrusion
Hot Drawing
Piercing
Squeezing: Cold Rolling, Cold
Forging , Cold Extrusion,
Coining, Peening, Burnishing,
and Thread Rolling.
Bending: Angle Bending, Roll
Bending, Roll-forming, and
Straightening.
Shearing: Slitting, Blanking,
Piercing, Notching, Nibbling,
Drawing: Spinning, Embossing,
Stretch Forming, and Ironing
Sheet-metal Forming
Operations
4. MI-102: Manufacturing Techniques I. I. T. ROORKEE
FORGING
Involves application of force on metal to
cause plastic deformation so as to get the
required final shape.
Forging is Generally a Hot Working but also
be Cold Forging.
Forging can be done in two ways
Drawing Out: Elongates the object with
a Reduction in the Cross-Sectional
Area using Force Applied in a Direction
Perpendicular to the longitudinal Axis.
Upsetting: increases the Cross-
Sectional Area of the Stock at the
Expense of its Length using Force
Applied in a Direction Parallel to the
Length Axis.
Drawing Out
Upsetting
5. MI-102: Manufacturing Techniques I. I. T. ROORKEE
FORGING TYPES
Smith Forging: Traditional Forging
performed using Open Dies with help of
Manual or Powered Hammers.
Drop Forging: uses Closed Impression
Dies by Means of Drop Hammers in a
Series of Blows.
Press Forging: is Similar to Drop Forging
with the Difference that the Force is a
Continuous Squeezing Type.
Machine Forging: the Material is only
Upset to Get the Desired Shape using a set
of dies.
7. MI-102: Manufacturing Techniques I. I. T. ROORKEE
SMITH FORGING
Involves Heating the Stock in the Blacksmith's Hearth and
then Beating it Over the Anvil.
The stock is Manipulated in Between the Blows.
Used for low volume production of variety of designs.
8. MI-102: Manufacturing Techniques I. I. T. ROORKEE
The Drop Forging Die Consists of Two Halves.
The Lower Half is Fixed to the Anvil of the
Machine,
While the Upper Half of the Die is Fixed to
the Ram.
The Heated Material Stock is Kept in the
Lower Die while the Ram Delivers Four to
Five Blows on the Material, in Quick
Succession so that the Material Spreads and
Completely Fills the Die Cavity.
When the Two Die Halves Close, the
Complete Cavity is Formed.
Since the Machined impressions in the Die
Cavity help to get more Complex Shapes in
Drop Forging as Compared to Smith Forging
10. MI-102: Manufacturing Techniques I. I. T. ROORKEE
Typical Products Produced by Drop Forging are Crank, Crank
Shaft, Connecting Rod, Wrench, Crane Hook, etc.
Final Shape Desired in Drop Forging Cannot be Obtained
Directly from the Stock in a Single Pass.
Depending on the Shape of the Component, and the Desired
Grain Flow Direction, the Material should be Manipulated
in a Number of Passes.
11. MI-102: Manufacturing Techniques I. I. T. ROORKEE
FULLERING IMPRESSION: Reducing Stock to the
Desired Size.
EDGING IMPRESSION (Preforming): Ensures
Defect-Free Flow of Material, Complete Die Fill and
Minimum Flash Loss.
BENDING IMPRESSION: for the Parts having a
Bent Shape.
BLOCKING is a Step before Finishing. The Material
Flows to Deep Pockets, Sharp Corners, etc.
before the Finishing Impression without Flash.
FINISHING: is the Final Impression for Actual
Shape .at this stage a Little Extra Material is
Added to the Stock Forms the Flash and
Surrounds the Forging in the Parting Plane.
TRIMMING is removal of the Extra Flash Present
Around the Forging to make the Forging in Usable
.
12. MI-102: Manufacturing Techniques I. I. T. ROORKEE
In Press Forging, involves Single Continuous Squeezing
Action results in Uniform Deformation Throughout the
Depth.
The Impressions Produced in the Press Forging are
Cleaner as Compared to the Jarred Impressions Produced
in the Drop Forged Components.
Press forging suits for smaller size components than drop
forging as former needs higher Press Capacity for Deforming
in Closed Impression Dies. No such Limitation for Press
Forging in Open Dies.
Presses Capacities May Range from 5 MN to 50 MN for
Normal Applications and as High as 600 MN for Special
Heavy Duty Applications.
PRESS FORGING
13. MI-102: Manufacturing Techniques I. I. T. ROORKEE
Initially Developed for Making the Bolt Heads in a
Continuous Fashion.
Due to Beneficial Grain Flow Obtained in Upsetting, it is Used
for Making Gear Blanks, Shafts, Axles and Similar Parts.
Some Typical Parts Produced by Upset Forgings are Shown in
the Figure.
The Die Set Consists of a Die and a Corresponding Punch or a
Heading Tool.
MACHINE FORGING
14. MI-102: Manufacturing Techniques I. I. T. ROORKEE
The Upset Forging Cycle
Movable Die comes closer to Stationary Die to Grip
the Stock.
The Two Dies in Closed Position Form the
Necessary Die Cavity.
The Punch Upsets stock to Fill the Die Cavity.
After Upsetting, Punch Moves Back to its Position.
Movable Grippes Release the Stock.
Similar to Drop Forging, the Upsetting Operation is
Carried Out in a Number of Stages or Passes.
The Material Stock is Moved from One Stage to the
Other in a Proper Sequence Till the Final Forging is
Ready.
MACHINE FORGING
16. MI-102: Manufacturing Techniques I. I. T. ROORKEE
FORGING DEFECTS
Unfilled Sections: of Die Cavity by the Flowing Material due to:
Improper Design of Forging Die or
Faulty Forging Techniques.
Cold Shut: A Small Crack at the Corners of the Forging due to
Improper Design of the Die e.g. Corner and Fillet Radii are
Small which in turn results in small cracks due to poor flow of
materials at the Corner.
Scale Pits: Irregular Depressions on the Surface of the Forging
primarily due to improper Cleaning of the Stock Used for Forging.
The Oxide and Scale Present on the Stock Surface Gets
Embedded into the Finished Forging Surface. When the Forging
is Cleaned by Pickling, these are Seen as Depressions on the
Forging Surface.
17. MI-102: Manufacturing Techniques I. I. T. ROORKEE
Die Shift:
CAUSES: Die Shift is Caused by the
Misalignment of the Two Die Halves
Making the Two Halves of the Forging to
be of Improper Shape.
Flakes: These are Basically Internal
Ruptures due to poor ductility of surface
layer during deformation caused by Rapid
Cooling
18. MI-102: Manufacturing Techniques I. I. T. ROORKEE
ROLLING
Rolling is a Process where the Material is Compressed
Between Two Rotating Rolls for Reducing its Cross-
Sectional Area.
Rolling is Normally a Hot Working Process unless specified
as Cold Rolling.
At Entry, the Surface Speed of Rolls is Higher than that of
the Incoming Material, whereas the Material Velocity at the
Exit is Higher than that of the Surface Speed of the Rolls
due to difference cross sectional area.
20. MI-102: Manufacturing Techniques I. I. T. ROORKEE
Rougher Rolls Achieve Greater Reduction than Smoother
Rolls. But, the Rough Roll Surface may Get Embedded into
the Rolled Metal thus Producing Rough Surface.
The Reduction that could be Achieved with a Given Set of Rolls
is Designated as the Angle of Bite. This Depends on the Type of
Rolling and the Conditions of the Rolls as shown in Table.
21. MI-102: Manufacturing Techniques I. I. T. ROORKEE
ROLLING STAND
2-High Reversing Rolling
Stand:
Direction of Roll Rotation
can be Reversed these
reduce Handling of the
Hot Material in Between
the Rolling Passes.
22. MI-102: Manufacturing Techniques I. I. T. ROORKEE
3-High Rolling Stand:
Arrangement is Used for Rolling of Two
Continuous Passes in a Rolling Sequence
without Reversing the Drives.
A Table-Tilting Arrangement is
Required to Bring the Material to the
Level with the Rolls.
23. MI-102: Manufacturing Techniques I. I. T. ROORKEE
4-High Rolling Stand:
Backup Rolls for Providing the Necessary Rigidity to the
Small Rolls.
24. MI-102: Manufacturing Techniques I. I. T. ROORKEE
Since Required Final Shape Cannot be Obtained in
a Single Pass
The Rolling Mills are Generally need More
than One Pass to other stands or by Reversing
the Roll Direction or
The Steel Ingot: 600 x 600 mm. These Ingots are
Further Processed in Rolling Mills to Produce the
Intermediate Shapes such as Blooms, Slabs and
Billets.
Blooms: 150 x 150 mm to 400 x 400 mm
(square).
Slabs: 500 to 1800 mm and Thickness from
50 to 300 mm (rectangle).
Billets: from 40 x 40 mm to 150 x 150 mm
(rectangle).
25. MI-102: Manufacturing Techniques I. I. T. ROORKEE
Roll Pass Sequence can be Broadly Categorized into
THREE Types:
1. Break Down Pass:
Used for Reducing the Cross-Sectional Area
Nearer to what is Desired.
2. Roughing Pass:
The Cross-Section Gets Reduced, but Shape of
the Rolled Material also Comes Nearer to the
Final Shape.
3. Finishing Pass:
Gives the Required Shape of the Rolled Section.
ROLL PASSES
26. MI-102: Manufacturing Techniques I. I. T. ROORKEE
DRAUGHT
If the Cross Section of the Product Before and
After Rolling Process is A x B and a x b Respectively,
DRAFT is Defined as (A + B)- (a + b)
Roll Pass Schedule can be obtained from
Draught.
If Mean Draught for Each Pass is Known, then
Number of Passes can be Estimated.
Draught Provided in Each Pass
also Depends on the
Work Material,
Angle of Bite,
Roll Strength,
Power of the Rolling Mill,
and
Condition of the Rolls.
27. MI-102: Manufacturing Techniques I. I. T. ROORKEE
Draughts of All the Passes in the Rolling
Sequence are NOT the Same.
The Main Criteria for Choosing the Draught
is the Angle of Bite.
Lower draught is used in subsequent passes.
Reason for Reducing Draught in the Later
Passes:
in Hot Rolling the Reduction in Stock
Thickness which Causes it to Lose Heat
Quickly and thus Increases the Rolling
Load.
in Cold Rolling, the Strain Hardening of the
Stock Material Necessitates a Reduction in
Draught in the Succeeding Passes.
Selection of draught
28. MI-102: Manufacturing Techniques I. I. T. ROORKEE
EXTRUSION
In Extrusion Process, the Material is Confined in a Closed Cavity
and then Forced to Flow From Only One Opening so that the
Material Takes the Shape of the Opening.
29. MI-102: Manufacturing Techniques I. I. T. ROORKEE
Used to Make Components having a Constant Cross-Section
over any Length.
More Complex Parts can be Obtained by Extrusion than
that of Rolling, as Die become Simple and Easier to
Make.
Extrusion is a Single Pass Process.
The Amount of Reduction Possible in Extrusion is Large.
Generally Brittle Materials can Also be Very Easily Extruded.
Typical
Extrusion
Shapes
30. MI-102: Manufacturing Techniques I. I. T. ROORKEE
Extrusion Ratio is Defined as the Ratio of
Cross-Sectional Area of the Billet to that of
the Extruded Section.
Typical Values of the Extrusion Ratio are 20
to 50.
The Extrusion Pressure for a Given Material
Depends on the
Extrusion Temperature,
Reduction in Area, and
Extrusion Speed
32. MI-102: Manufacturing Techniques I. I. T. ROORKEE
FORWARD HOT EXTRUSION
The Direction of Flow of Material is the Same as that of the
Ram.
Friction is Important Because of the Relative Motion
Between the Heated Material Billet and the Cylinder Walls.
Lubricants are to be used To Reduce this Friction.
Forward Extrusion
For Low
Temperatures:,
Oil Mixture and
Graphite
For High
Temperature,
Molten Glass
for Extruding
Steels.
33. MI-102: Manufacturing Techniques I. I. T. ROORKEE
BACKWARD or INDIRECT HOT EXTRUSION
The Ram Compresses the Material Against the Container,
Forcing the Material to Flow Backwards through the Die
in the Hollow Plunger or Ram.
Since Billet in the Container Remains Stationary No
Friction.
Backward Extrusion
Extrusion Pressure
is Not Affected by
the Length of the
Billet as friction in
absent
Problem is
imposed by
Handling Extruding
Material Coming
Out through the
Moving Ram.
34. MI-102: Manufacturing Techniques I. I. T. ROORKEE
FORWARD COLD EXTRUSION
Forward Cold Extrusion is Similar to the Forward Hot
Extrusion Process Except with low Extrusion Ratios and high
Extrusion Pressures.
Used for Simple Shapes with Better Surface Finish and
Mechanical Properties.
IMPACT EXTRUSION
It is modification of Backward Cold Extrusion Carried Out by
the Impact Force of the Punch.
Material is Extruded through the Gap Between the Punch
and Die Opposite to the Punch Movement.
Suitable for Softer Materials such as Aluminum and its
Alloys.
Used for Making the Collapsible Tubes for Housing Pastes,
Liquids and similar Articles.
36. MI-102: Manufacturing Techniques I. I. T. ROORKEE
COLD EXTRUSION FORGING:
The Cold Extrusion Forging is Similar to Impact
Extrusion, the
Main Difference being the Side Walls much Thicker
and with More Height.
The Component is Ejected by Means of the Ejector Pin
Provided in the Die
37. MI-102: Manufacturing Techniques I. I. T. ROORKEE
HYDROSTATIC EXTRUSION:
The Material Billet is Compressed from all Sides by
a Liquid Rather than the Ram.
The Material is Uniformly Compressed from All
Sides throughout the Deformation Zone.
Consequently Highly Brittle Materials such as
Grey Cast Iron can also be Extruded.
Commercial Applications of the Hydrostatic
Extrusion are Limited to
Extrusion of Reactor Fuel Rods,
Cladding of Metals, and
Making Wires of Less Ductile Materials.
39. MI-102: Manufacturing Techniques I. I. T. ROORKEE
WIRE DRAWING
Wire Drawing is a cold working process to Obtain Wires
from Rods of Bigger Diameter through a Die.
The End of the Rod is Made into a Point Shape and
Inserted through the Die Opening then Pull the Wire
through the Die with help of griper
Material to be Wire Drawn should be Sufficiently Ductile.
DRAWING
40. MI-102: Manufacturing Techniques I. I. T. ROORKEE
Wire Drawing Set Up
Various Die Materials Used are Chilled Cast Iron,
Tool Steels, Alloy Steels, Tungsten Carbide and Diamond.
41. MI-102: Manufacturing Techniques I. I. T. ROORKEE
In Tube Drawing, a Mandrel of the Requisite Diameter is
Used to Form the Internal Hole.
The Tubes are also First Pointed and then Entered through
the Die where the Point is Gripped in Similar way as the
Wire Drawing and Pulled Through.
TUBE DRAWING
42. MI-102: Manufacturing Techniques I. I. T. ROORKEE
SHEET METAL OPERATIONS
Metal Sheet: Plates of thickness < 5 mm
Sheet metal operations use different types
of stresses for processing
Shear stress is primarily used in sheet
metal processing
Stress Induced Operations
Shearing Shearing, Blanking, Piercing,
Trimming, Shaving, Notching,
Nibbling
Tension Stretch-Forming
Compression Ironing, Coining
Tension and
Compression
Drawing, Spinning, Bending,
Embossing, Forming
43. MI-102: Manufacturing Techniques I. I. T. ROORKEE
SHEARING
The Sheet IS deformed between two shearing
Blades (developing tensile and compressive stress).
Then cracks nucleate and grow when material near
cutting edges is elongated beyond fracture limit which
later join for separation.
44. MI-102: Manufacturing Techniques I. I. T. ROORKEE
BLANKING:
Process of obtaining a small piece of strip by cutting
(shearing from the Stock with help of a Punch.
The removed strip is Called Blank used for further
processing to get useable product.
Blanking/Punching Die
PUNCHING:
Similar to blanking
except
that objective is to
make Holes in
Sheet
and removed strip is
considered as scrap
47. MI-102: Manufacturing Techniques I. I. T. ROORKEE
TRIMMING:
Removing Small Amount of Extra Material Spread Out Near
the Parting Plane such as Drop Forging and Die Casting.
SHAVING
Removal of the Burrs Generated during the Shearing Process
in the Blanking or Punching Operation so as to achieve the
Close Tolerance Work.
NIBBLING:
Removing the Material in Small Increments to Cut a Specific
Contour on a Sheet using repeating Punching.
Nibbling is Used When the Contour is Long and a Separate
Punch is Impractical and Uneconomical.
NOTCHING: Cutting a Specified Small Portion of Material
Towards the Edge of the Material Stock.
49. MI-102: Manufacturing Techniques I. I. T. ROORKEE
STRETCH-FORMING
The Sheet is Clamped at ends and Stretched over the
Die so as to achieve plastic State and permanent
deformation.
SHEET METAL OPERATIONS INVOLVING
TENSION
51. MI-102: Manufacturing Techniques I. I. T. ROORKEE
IRONING
It involves thinning and lengthening of the wall
of material by generating compressive stress
between the Die and Punch having using the
Clearance (spacing) finer than the Drawing
Operation.
Up to 50%
thinning can
be obtained in
a Single
Ironing
Operation
Ironing Operation
SHEET METAL OPERATIONS INVOLVING COMPRESSION
52. MI-102: Manufacturing Techniques I. I. T. ROORKEE
COINING
It is just like a Cold Forging Operation except that the
Flow of the Material Occurs Only at the Top Layers
and NOT in the Entire Volume.
The Punch and Die have Engraved Details Required on
Both Sides of the Final Object and uses high pressure
(1600 MPa) to get Fine Details on the Surface.
For Making
Coins, Medals
& Impressions
on Decorative
Items
53. MI-102: Manufacturing Techniques I. I. T. ROORKEE
DRAWING/DEEP DRAWING
Drawing is the Process of Making Cups (high < half
diameter), and similar product, from Metal Blanks.
When the Cup Height is More than Half the Diameter, the
Drawing Process is known as Deep Drawing.
SHEET METAL OPERATIONS INVOLVING
TENSION and COMPRESSION
55. MI-102: Manufacturing Techniques I. I. T. ROORKEE
SPINNING
Used for Making Axi-Symmetrical Cup Shaped Articles.
Force (moving) is Applied on the Rotating Blank is Held
Against the Form Block so as get Shape of the Form Block
(of wood).
56. MI-102: Manufacturing Techniques I. I. T. ROORKEE
BENDING
Operation of Deforming a Flat Sheet Around a Straight
Axis at the Neutral Plane.
When material is subjected to plastic deformation, the
Neutral Axis Moves Downward due to differential strain
on both sides of neutral axis as the Materials Oppose
Compression in much Better way than Tension.
Nomenclature of Bending and Type of Bending Methods
are Shown in Following Figures.
59. MI-102: Manufacturing Techniques I. I. T. ROORKEE
EMBOSSING
An Operation for Making Raised Figures/letter on
Sheets with its Corresponding Relief on the Other Side.
The Process Involves Drawing and Bending of the
Material.
Generally Used for increasing the Rigidity by localized
deformation and for Decorative Sheet Work.