The document discusses various metal forming processes including forging, rolling, extrusion, and drawing. It describes the key characteristics of these processes. Forging involves shaping metals using compressive forces and can be done hot or cold. Rolling is used to reduce the thickness and alter the shape of metal strips and involves passing the metal between rolls. Extrusion uses either hot or cold compression to push metal through a die to take on a continuous cross-section. Drawing reduces the cross-sectional area and increases the length of metals by pulling them through a die.
The document provides an overview of the theory of metal cutting. It discusses the mechanics of chip formation, types of chips, cutting tools and their components/angles. It also describes the metal cutting process, orthogonal vs oblique cutting, thermal aspects of cutting, tool wear and life, factors affecting surface finish and machinability. Cutting fluids, their functions and types are also summarized.
This document discusses various metal forming processes including forging, rolling, drawing, and extrusion. It provides details on:
1) Hot and cold working of metals, types of forging processes, characteristics of forging, types of forging machines, and common forging operations.
2) Types of rolling mills and rolling processes like flat strip rolling and shape rolling. It also discusses defects in rolled parts.
3) Principles and types of drawing and extrusion processes. Drawing processes include wire, rod, tube, and deep drawing. Extrusion can be hot or cold.
moloy roy tool technology presentationAkash Maurya
This document discusses cutting tool technology, including different tool materials, tool geometries, and cutting fluids. It describes the three main modes of tool failure as fracture, temperature, and gradual wear. High speed steel and cemented carbides are introduced as common tool materials, along with their properties and applications. Various tool geometries are covered, including single-point tools, twist drills, and milling cutters. Finally, the roles of cutting fluids in cooling and lubricating during machining operations are summarized.
The document discusses various sheet metal processes including shearing, bending, drawing, and special forming processes. It provides details on:
- Common shearing operations like punching, blanking, and notching used to cut sheet metal.
- Forming processes like bending, stretching, and drawing that cause shape changes without cracking or excessive thinning.
- Special high-pressure forming techniques like hydroforming, rubber pad forming, spinning, and super plastic forming.
- Factors that influence formability and properties of sheet metals like strength, ductility, formability, and factors that affect drawing operations.
Metal forming process, Non chip forming machining processSuyog Lokhande
Mechanical forming processes include rolling, forging, and extrusion. Rolling involves passing metal through opposing rollers to reduce thickness. Forging involves compressing metal between dies or a hammer to shape it. Extrusion uses a container and die to force metal through an opening to create a shape. These processes deform metal through compression and are used to make common parts like gears, aircraft components, and tubing.
The document provides an overview of the theory of metal cutting. It discusses the mechanics of chip formation, types of chips, cutting tools and their components/angles. It also describes the metal cutting process, orthogonal vs oblique cutting, thermal aspects of cutting, tool wear and life, factors affecting surface finish and machinability. Cutting fluids, their functions and types are also summarized.
This document discusses various metal forming processes including forging, rolling, drawing, and extrusion. It provides details on:
1) Hot and cold working of metals, types of forging processes, characteristics of forging, types of forging machines, and common forging operations.
2) Types of rolling mills and rolling processes like flat strip rolling and shape rolling. It also discusses defects in rolled parts.
3) Principles and types of drawing and extrusion processes. Drawing processes include wire, rod, tube, and deep drawing. Extrusion can be hot or cold.
moloy roy tool technology presentationAkash Maurya
This document discusses cutting tool technology, including different tool materials, tool geometries, and cutting fluids. It describes the three main modes of tool failure as fracture, temperature, and gradual wear. High speed steel and cemented carbides are introduced as common tool materials, along with their properties and applications. Various tool geometries are covered, including single-point tools, twist drills, and milling cutters. Finally, the roles of cutting fluids in cooling and lubricating during machining operations are summarized.
The document discusses various sheet metal processes including shearing, bending, drawing, and special forming processes. It provides details on:
- Common shearing operations like punching, blanking, and notching used to cut sheet metal.
- Forming processes like bending, stretching, and drawing that cause shape changes without cracking or excessive thinning.
- Special high-pressure forming techniques like hydroforming, rubber pad forming, spinning, and super plastic forming.
- Factors that influence formability and properties of sheet metals like strength, ductility, formability, and factors that affect drawing operations.
Metal forming process, Non chip forming machining processSuyog Lokhande
Mechanical forming processes include rolling, forging, and extrusion. Rolling involves passing metal through opposing rollers to reduce thickness. Forging involves compressing metal between dies or a hammer to shape it. Extrusion uses a container and die to force metal through an opening to create a shape. These processes deform metal through compression and are used to make common parts like gears, aircraft components, and tubing.
The document provides information about workshop technology and machine shop theory. It discusses various topics like metal cutting, lathe machine, drilling machine, shaper, planer, slotter machine, and milling machine. For lathe machine, it describes the types of lathe, construction of lathe, accessories and attachments used in lathe like lathe centers, lathe dog, chuck, faceplate, angle plate, and mandrels. It also provides details about metal cutting processes, types of chips, cutting tools, and use of coolants in metal cutting.
Metal Cutting Tools : Factors affecting Tool's lifeBipico Industries
Metal cutting tools are an indispensable part of manufacturing and industrial production. Right metal cutting tool can enhance the manufacturing process with its efficiency and effectiveness. Cutting tool life is an important consideration in metal cutting processes. The life of metal cutting tool is influenced by many factors which should be duly considered at the time of buying and using the tools. Here are some of the major factors that decide the life of your metal cutting tool.
This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
The major drawback of the process is loss of material in the form of chips. In this chapter. we shall have a fundamental understanding of the basic metal process.
Unit -1-Theory of Metal Cutting
Manufacturing Technology is much more essential subjects for Mechanical Engineering According that i am prepare study material for Manufacturing Technology-2 UNIT wise ......1 st unit covered more then enough for this materials get wide knowledge from Manufacturing Division.....
All The Best My Dear Hearts
Remaining Units i will update soon ....
Thank you ....
By: Prof.S.Sathishkumar
This document discusses machine tools and machining processes. It covers topics such as cutting tools, tool selection factors, tool design and terminology, forces in metal cutting, tool life, cutting speeds and feeds, tool failure modes, machinability, cutting inserts, and cutting fluids. The document is presented by Vikrant Sharma of the Mechanical Engineering department and contains diagrams to illustrate machining concepts.
The document discusses metal cutting processes and lathe machines. It begins by defining metal cutting as the process of removing unwanted material from a block of metal in the form of chips using relative motion between the tool and workpiece. It then classifies metal cutting into orthogonal and oblique cutting. Finally, it discusses the various parts and operations of a lathe machine, including the headstock, carriage, tooling, workholding devices, and taper turning methods.
This document discusses metal cutting and cutting tools. It describes metal cutting as the process of removing unwanted material from a block of metal using a cutting tool. There are two types of cutting processes: continuous contact cutting like turning and drilling, and intermittent cutting like milling and grinding. Cutting tools are used to remove metal through shear deformation and can have a single point or multiple points. The document then discusses different types of cutting tools, motions in cutting operations, orthogonal and oblique cutting, ideal properties of cutting tool materials, major cutting tool materials like high speed steel and cemented carbides, applications of different materials, and disadvantages of prominent materials.
01 introduction to Manufacturing processesM Siva Kumar
Manufacturing processes can be grouped into casting/molding, forming, machining, joining/assembly, surface treatments, and heat treating. A manufacturing system includes the operations and processes to produce a product, while a production system also includes people, equipment, materials, markets, management, and the manufacturing system. Common machining processes include turning, milling, drilling, grinding, tapping, hobbing, broaching, and advanced processes like electrical discharge machining, laser beam machining, and water jet cutting.
Lecture 1 metal cutting and machine tools unit iSerajul Haque
The document discusses the objectives and modules of a course on metal cutting and machine tools. The objectives include studying material removal processes, learning about lathes, milling machines, drilling, broaching, and gear cutting, and gaining knowledge of CNC machine tools and advanced machining methods. The modules cover theory of metal cutting, lathes, reciprocating machines, milling, drilling/broaching/gear cutting, finishing processes, and CNC/modern machining. Key aspects of metal cutting discussed are the geometry of single point cutting tools, chip formation, forces, tool wear, and cutting fluids.
The document discusses various topics related to machining processes including:
- The objectives of understanding machining processes and estimating machining time and costs.
- The mechanics of chip formation during metal cutting using single-point cutting tools.
- Factors that influence tool life such as cutting speed, feed rate, depth of cut, tool geometry, and work material.
- Different types of chips produced during machining such as continuous, discontinuous, and chips with a built-up edge.
- Properties required for cutting tool materials including hardness, wear resistance, toughness, thermal conductivity and elements commonly used.
- Common cutting tool materials including high-carbon steel, high-speed steel, cemented carbides
Sand casting is a process for producing metal parts by pouring molten metal into a sand mould cavity. Key steps include making patterns to form the mould cavity, using various types of sand like green sand with moisture and clay, and testing properties of moulding sand. Special casting processes include shell mould casting, investment casting and lost wax process. Castings are inspected using visual, magnetic particle, dye penetrant and ultrasonic methods to find internal and surface defects.
This document provides an overview of shearing and bending processes, including:
1) Shearing involves cutting sheet metal using a punch and die, while bending deforms metal around a straight axis using tools like a finger brake.
2) The lab objectives are to familiarize students with shearing and bending and analyze springback in aluminum bending.
3) Finite element analysis simulations demonstrate the deformation and springback during bending.
The document defines a lathe as a machine that removes metal from a workpiece to shape it. A lathe operates by rotating the workpiece while a fixed cutting tool is fed into it. Key components of a lathe include the bed, carriage, headstock, tailstock, and feed rod. Common types of lathes are engine lathes, bench lathes, speed lathes, automatic lathes, turret lathes, and computer controlled lathes. Basic lathe operations include turning, facing, boring, drilling, reaming, threading, and knurling.
Metal cutting involves removing unwanted material from a workpiece. In orthogonal cutting, the cutting tool edge is perpendicular to the direction of motion, so chip flow is perpendicular to the cutting edge. In oblique cutting, the cutting tool edge is at an angle to the direction of motion, so chip flow is sideways. Orthogonal cutting results in higher heat concentration, shorter tool life, and poorer surface finish than oblique cutting. Oblique cutting is used for most industrial processes like drilling and milling.
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.
Mp 1-unit - iii - metal forming processeskarthi keyan
The document discusses various metal forming processes including hot working, cold working, and forging processes. It provides details on processes like hot/cold rolling, extrusion, drawing, spinning, and forging. It explains that hot working involves plastic deformation of metals above the recrystallization temperature, while cold working is performed below this temperature. The advantages and limitations of hot and cold working are also summarized.
The document provides information about workshop technology and machine shop theory. It discusses various topics like metal cutting, lathe machine, drilling machine, shaper, planer, slotter machine, and milling machine. For lathe machine, it describes the types of lathe, construction of lathe, accessories and attachments used in lathe like lathe centers, lathe dog, chuck, faceplate, angle plate, and mandrels. It also provides details about metal cutting processes, types of chips, cutting tools, and use of coolants in metal cutting.
Metal Cutting Tools : Factors affecting Tool's lifeBipico Industries
Metal cutting tools are an indispensable part of manufacturing and industrial production. Right metal cutting tool can enhance the manufacturing process with its efficiency and effectiveness. Cutting tool life is an important consideration in metal cutting processes. The life of metal cutting tool is influenced by many factors which should be duly considered at the time of buying and using the tools. Here are some of the major factors that decide the life of your metal cutting tool.
This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
The major drawback of the process is loss of material in the form of chips. In this chapter. we shall have a fundamental understanding of the basic metal process.
Unit -1-Theory of Metal Cutting
Manufacturing Technology is much more essential subjects for Mechanical Engineering According that i am prepare study material for Manufacturing Technology-2 UNIT wise ......1 st unit covered more then enough for this materials get wide knowledge from Manufacturing Division.....
All The Best My Dear Hearts
Remaining Units i will update soon ....
Thank you ....
By: Prof.S.Sathishkumar
This document discusses machine tools and machining processes. It covers topics such as cutting tools, tool selection factors, tool design and terminology, forces in metal cutting, tool life, cutting speeds and feeds, tool failure modes, machinability, cutting inserts, and cutting fluids. The document is presented by Vikrant Sharma of the Mechanical Engineering department and contains diagrams to illustrate machining concepts.
The document discusses metal cutting processes and lathe machines. It begins by defining metal cutting as the process of removing unwanted material from a block of metal in the form of chips using relative motion between the tool and workpiece. It then classifies metal cutting into orthogonal and oblique cutting. Finally, it discusses the various parts and operations of a lathe machine, including the headstock, carriage, tooling, workholding devices, and taper turning methods.
This document discusses metal cutting and cutting tools. It describes metal cutting as the process of removing unwanted material from a block of metal using a cutting tool. There are two types of cutting processes: continuous contact cutting like turning and drilling, and intermittent cutting like milling and grinding. Cutting tools are used to remove metal through shear deformation and can have a single point or multiple points. The document then discusses different types of cutting tools, motions in cutting operations, orthogonal and oblique cutting, ideal properties of cutting tool materials, major cutting tool materials like high speed steel and cemented carbides, applications of different materials, and disadvantages of prominent materials.
01 introduction to Manufacturing processesM Siva Kumar
Manufacturing processes can be grouped into casting/molding, forming, machining, joining/assembly, surface treatments, and heat treating. A manufacturing system includes the operations and processes to produce a product, while a production system also includes people, equipment, materials, markets, management, and the manufacturing system. Common machining processes include turning, milling, drilling, grinding, tapping, hobbing, broaching, and advanced processes like electrical discharge machining, laser beam machining, and water jet cutting.
Lecture 1 metal cutting and machine tools unit iSerajul Haque
The document discusses the objectives and modules of a course on metal cutting and machine tools. The objectives include studying material removal processes, learning about lathes, milling machines, drilling, broaching, and gear cutting, and gaining knowledge of CNC machine tools and advanced machining methods. The modules cover theory of metal cutting, lathes, reciprocating machines, milling, drilling/broaching/gear cutting, finishing processes, and CNC/modern machining. Key aspects of metal cutting discussed are the geometry of single point cutting tools, chip formation, forces, tool wear, and cutting fluids.
The document discusses various topics related to machining processes including:
- The objectives of understanding machining processes and estimating machining time and costs.
- The mechanics of chip formation during metal cutting using single-point cutting tools.
- Factors that influence tool life such as cutting speed, feed rate, depth of cut, tool geometry, and work material.
- Different types of chips produced during machining such as continuous, discontinuous, and chips with a built-up edge.
- Properties required for cutting tool materials including hardness, wear resistance, toughness, thermal conductivity and elements commonly used.
- Common cutting tool materials including high-carbon steel, high-speed steel, cemented carbides
Sand casting is a process for producing metal parts by pouring molten metal into a sand mould cavity. Key steps include making patterns to form the mould cavity, using various types of sand like green sand with moisture and clay, and testing properties of moulding sand. Special casting processes include shell mould casting, investment casting and lost wax process. Castings are inspected using visual, magnetic particle, dye penetrant and ultrasonic methods to find internal and surface defects.
This document provides an overview of shearing and bending processes, including:
1) Shearing involves cutting sheet metal using a punch and die, while bending deforms metal around a straight axis using tools like a finger brake.
2) The lab objectives are to familiarize students with shearing and bending and analyze springback in aluminum bending.
3) Finite element analysis simulations demonstrate the deformation and springback during bending.
The document defines a lathe as a machine that removes metal from a workpiece to shape it. A lathe operates by rotating the workpiece while a fixed cutting tool is fed into it. Key components of a lathe include the bed, carriage, headstock, tailstock, and feed rod. Common types of lathes are engine lathes, bench lathes, speed lathes, automatic lathes, turret lathes, and computer controlled lathes. Basic lathe operations include turning, facing, boring, drilling, reaming, threading, and knurling.
Metal cutting involves removing unwanted material from a workpiece. In orthogonal cutting, the cutting tool edge is perpendicular to the direction of motion, so chip flow is perpendicular to the cutting edge. In oblique cutting, the cutting tool edge is at an angle to the direction of motion, so chip flow is sideways. Orthogonal cutting results in higher heat concentration, shorter tool life, and poorer surface finish than oblique cutting. Oblique cutting is used for most industrial processes like drilling and milling.
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.
Mp 1-unit - iii - metal forming processeskarthi keyan
The document discusses various metal forming processes including hot working, cold working, and forging processes. It provides details on processes like hot/cold rolling, extrusion, drawing, spinning, and forging. It explains that hot working involves plastic deformation of metals above the recrystallization temperature, while cold working is performed below this temperature. The advantages and limitations of hot and cold working are also summarized.
This document discusses various metal forming processes including forging, rolling, drawing, and extrusion. It provides details on hot working and cold working metals, types of forging machines and operations, flat and shape rolling, defects in rolled parts, principles of drawing rods, tubes and wires, and types of extrusion such as hot and cold extrusion. The key advantages and disadvantages of these metal forming techniques are also summarized.
Hot working and cold working of metals – Forging processes – Open, impression and closed die forging – Types of Forging Machines – Typical forging operations. Rolling of metals– Types of Rolling – Flat strip rolling – shape rolling operations – Defects in rolled parts. Principle of rod and wire drawing – Tube drawing – Principles and types of Extrusion – Hot and Cold extrusion.
This document discusses various metal forming processes including:
1. Hot and cold working processes such as forging, rolling, extrusion, and drawing. Forging can be open die, impression die, or closed die. Rolling can be flat or shape rolling.
2. The advantages of hot working include lower forces required, ability to produce dramatic shape changes, and potential to combine with casting. Cold working provides better surface finish and precision.
3. Extrusion uses compression to force metal through a die opening. It can produce hollow or complex cross-sections. Wire and bar drawing similarly reduce cross-section by pulling metal through a die.
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.
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 differences between smithy and forging processes. Key tools used in smithy like anvil, hammers, tongs, swages, and common forging operations like upsetting, drawing, bending, and punching are also summarized.
The document discusses various metal forming processes. It describes hot working and cold working of metals, where hot working involves shaping metals above their recrystallization temperature and cold working is below this temperature. Specific metal forming processes covered include forging processes like open die forging, closed die forging, and roll forging. Other forming methods discussed are drawing, extrusion, and bending. The advantages and limitations of hot and cold working are also compared.
The document discusses various metal forming processes. It describes hot working and cold working of metals, where hot working involves shaping metals above their recrystallization temperature and cold working is below this temperature. Specific metal forming processes covered include forging processes like open die forging, closed die forging, and roll forging. Other forming methods discussed are drawing, extrusion, and bending. The advantages and limitations of hot and cold working are also compared.
1) Metal forming is a process that changes the shape of metal parts through plastic deformation using processes like forging, rolling, and extrusion.
2) It provides advantages like reduced material costs and improved mechanical properties through working.
3) Forging is the process of heating metal to a plastic state and shaping it using hammers. It has types like open forging, closed forging, and drop forging.
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.
Introduction Hot Working and Cold Working of Metals Forging Processes- Open, impression die forging, Closed die forging-forging operation Rolling of metals-types of rolling- Flat strip rolling-shape rolling operation -Defects in rolled parts- Principle of rod and wire drawing-tube drawing -Principle of extrusion Types-hot and cold extrusion.
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.
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.
The document discusses various metal forming processes including forging. It defines forging as a process where a metal is heated and compressed in a die to obtain a final shape. The key types of forging are closed die forging using two dies and open die forging with simple shaped dies. Forging can be done hot or cold based on the temperature of the workpiece. Common forging operations aim to reduce cross-sectional area or change thickness. Forging produces grain structures that improve mechanical properties.
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.
Forging is a metalworking process that involves shaping a solid metal workpiece using compressive forces. Common forging operations include upsetting, edging, fullering, drawing, swaging, piercing, punching, and bending. Forging is often done using machines like drop hammers, power hammers, hydraulic presses, mechanical presses, and friction screw presses. Proper die and process design is important to produce quality forgings and avoid defects from issues like die misalignment, incomplete filling, or cracking.
This document discusses the calculation of machining time for various operations. It begins by explaining why machining time calculation is important for cost estimation. It then provides formulas and factors to consider for calculating machining time for lathe operations like turning, facing, knurling, reaming, tapping and threading. It also discusses calculating time for other operations like drilling, boring, milling, shaping, planning and grinding. The key factors considered include tool travel, feed, depth of cut, rpm, cutting speed, setup time, operation time, tear down time and allowances. The document emphasizes the importance of accurately estimating machining time for determining total production costs.
This document discusses cost estimation for different manufacturing processes including forging, welding, and foundry. It provides details on estimating material, labor, and overhead costs for each process. For forging, it describes various forging operations and how to calculate material and labor costs. For welding, it defines different joint types and explains how to estimate costs for materials, pre/post welding labor, power, and overheads. For foundries, it outlines the process and provides a brief overview of the key sections.
This document discusses cost estimation in manufacturing. It defines cost estimation as predicting production costs before manufacturing begins. The general cost estimation procedure involves estimating costs for design, materials, labor, tools/fixtures, overhead, etc. It provides details on estimating each of these cost elements and notes that accurate estimates require data from various departments on specifications, drawings, production rates, testing procedures, and more. The overall purpose of cost estimation is to help management decide whether to produce a product and what price to set.
This document discusses the topics of a course on process planning and cost estimation. The course covers process planning activities, an introduction to cost estimation, production cost estimation, and machining time calculation. It also discusses quality assurance methods, quality strategies, statistical quality tools, control charts, measurement instruments, and factors to consider when selecting measuring instruments.
This document discusses process planning and cost estimation for manufacturing. It covers the stages of process planning like drawing interpretation, material selection, process and machine selection. It details the information that can be obtained from engineering drawings for process planning like material, dimensions, tolerances etc. It also explains factors considered for machine and tool selection like manufacturing process, part geometry, tool materials etc. The document provides information on process planning activities from design to cost estimation for production.
Mr. N. Sivashankar holds an M.E. and Ph.D. in engineering. He thanks an unnamed recipient for an unspecified reason. The document expresses gratitude but provides little context about its purpose or content.
PRODUCTION PLANNING AND CONTROL unit 5.pptSIVASHANKAR N
Inventory control aims to ensure adequate supply without excessive overstock. It answers questions about when to order, where to store inventory, and how much to order. Two common inventory management techniques are the two-bin system and economic order quantity (EOQ) modeling, which aim to minimize total inventory costs. ABC analysis categorizes inventory into A, B, and C items to allow for different control and record-keeping based on importance and cost.
The document discusses various production scheduling concepts and methods. It describes the functions of loading and scheduling, including determining operation times and adding work to schedules. Common scheduling benefits are outlined as well as tools like Gantt charts, line of balance diagrams, and MRP. Batch production scheduling, linear scheduling, dispatching, progress reporting and manufacturing lead times are also summarized.
Product planning identifies market requirements to define a product's features. It serves as the basis for pricing, distribution, and promotion decisions. Value analysis aims to increase value, defined as function over cost, by improving function or reducing cost. Lack of product planning can lead to unsatisfied customers, quality issues, and loss of brand name. Process planning involves routing, scheduling, dispatching, and follow up based on product information, processes, capacity, orders, due dates, and resources. Economic batch quantity determines the optimal batch size to minimize average costs by balancing setup costs and inventory holding costs.
The document discusses work study and method study. It provides details on the basic procedures for method study which include selecting work to study, recording the existing method, examining the facts critically, developing a more efficient method, defining the new method, installing it, and maintaining it. It describes various charts that can be used for process recording like operation process charts, flow process charts, two-handed process charts, and string diagrams. The objectives and principles of motion study are also summarized.
This document discusses production planning and control. It outlines several key objectives of production planning including minimizing costs and inventory while maximizing customer service and production efficiency. The document then describes different types of production systems like continuous, job-based, and intermittent production. It also discusses important aspects of production like product design, development, marketing, functional operations, aesthetics, and profit considerations. Standardization, simplification, and break-even analysis are also covered as important strategies for production.
1) A belt drive transfers rotary motion between two shafts using one or more continuous belts looped over a pulley on each shaft. Belts come in various types like flat, round, V-shaped, and toothed belts for different applications.
2) Common belt drive arrangements include open drives with parallel shafts rotating in the same direction, crossed drives with parallel shafts rotating in opposite directions, and compound drives using multiple pulleys. Idler pulleys are also used to adjust tension and increase contact area.
3) Belt drives are used widely in machinery and vehicles to transmit power economically over varying distances and speeds depending on the belt and pulley type.
This document provides information on numerical control (NC) and computer numerical control (CNC) machine tools. It discusses the basic components and classification of NC machines, types of numerical control systems, and part programming fundamentals for CNC machines. The document also covers topics like micromachining, wafer machining, and manual part programming for CNC machines.
The document discusses abrasive processes and broaching. It describes various grinding wheel specifications and types of grinding machines. The key types of grinding machines are cylindrical grinding machines, surface grinding machines, and internal grinding machines. It also discusses broaching machines, broach construction, and different types of broaching such as push, pull, surface, and continuous broaching. Broaching is used to machine surfaces using a special cutting tool called a broach.
DEEP LEARNING FOR SMART GRID INTRUSION DETECTION: A HYBRID CNN-LSTM-BASED MODELgerogepatton
As digital technology becomes more deeply embedded in power systems, protecting the communication
networks of Smart Grids (SG) has emerged as a critical concern. Distributed Network Protocol 3 (DNP3)
represents a multi-tiered application layer protocol extensively utilized in Supervisory Control and Data
Acquisition (SCADA)-based smart grids to facilitate real-time data gathering and control functionalities.
Robust Intrusion Detection Systems (IDS) are necessary for early threat detection and mitigation because
of the interconnection of these networks, which makes them vulnerable to a variety of cyberattacks. To
solve this issue, this paper develops a hybrid Deep Learning (DL) model specifically designed for intrusion
detection in smart grids. The proposed approach is a combination of the Convolutional Neural Network
(CNN) and the Long-Short-Term Memory algorithms (LSTM). We employed a recent intrusion detection
dataset (DNP3), which focuses on unauthorized commands and Denial of Service (DoS) cyberattacks, to
train and test our model. The results of our experiments show that our CNN-LSTM method is much better
at finding smart grid intrusions than other deep learning algorithms used for classification. In addition,
our proposed approach improves accuracy, precision, recall, and F1 score, achieving a high detection
accuracy rate of 99.50%.
KuberTENes Birthday Bash Guadalajara - K8sGPT first impressionsVictor Morales
K8sGPT is a tool that analyzes and diagnoses Kubernetes clusters. This presentation was used to share the requirements and dependencies to deploy K8sGPT in a local environment.
A SYSTEMATIC RISK ASSESSMENT APPROACH FOR SECURING THE SMART IRRIGATION SYSTEMSIJNSA Journal
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.
Introduction- e - waste – definition - sources of e-waste– hazardous substances in e-waste - effects of e-waste on environment and human health- need for e-waste management– e-waste handling rules - waste minimization techniques for managing e-waste – recycling of e-waste - disposal treatment methods of e- waste – mechanism of extraction of precious metal from leaching solution-global Scenario of E-waste – E-waste in India- case studies.
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
Electric vehicle and photovoltaic advanced roles in enhancing the financial p...IJECEIAES
Climate change's impact on the planet forced the United Nations and governments to promote green energies and electric transportation. The deployments of photovoltaic (PV) and electric vehicle (EV) systems gained stronger momentum due to their numerous advantages over fossil fuel types. The advantages go beyond sustainability to reach financial support and stability. The work in this paper introduces the hybrid system between PV and EV to support industrial and commercial plants. This paper covers the theoretical framework of the proposed hybrid system including the required equation to complete the cost analysis when PV and EV are present. In addition, the proposed design diagram which sets the priorities and requirements of the system is presented. The proposed approach allows setup to advance their power stability, especially during power outages. The presented information supports researchers and plant owners to complete the necessary analysis while promoting the deployment of clean energy. The result of a case study that represents a dairy milk farmer supports the theoretical works and highlights its advanced benefits to existing plants. The short return on investment of the proposed approach supports the paper's novelty approach for the sustainable electrical system. In addition, the proposed system allows for an isolated power setup without the need for a transmission line which enhances the safety of the electrical network
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.
ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
1. METAL FORMING PROCESSES
Hot working and cold working of metals – Forging processes – Open,
impression and closed die forging – Characteristics of the process – Types of
Forging Machines – Typical forging operations – Rolling of metals – Types
of Rolling mills - Flat strip rolling – Shape rolling operations – Defects in
rolled parts - Principle of rod and wire drawing -Tube drawing –– Principles
of Extrusion – Types of Extrusion – Hot and Cold extrusion – Equipments
used.
2. HOT WORKING OF METALS
Mechanical working of a metal above the recrystallization temperature
but below the melting point.
Plastic deformation of metals and alloys under the condition of
temperature and strain rate.
Recrystallization temperature is 30 to 40% of melting temperature.
In this process, Metal is heated above the RT with 0.7 to 0.9 times of the
melting temperature.
TYPES OF HOT WORKING PROCESS
-Hot forging
-Hot Rolling
-Hot Extrusions
-Drawing
-Swaging
-Hot Spinning
7. Hot spinning
Metal spinning, also known as spin forming or
spinning or metal turning most commonly, is a
metalworking process by which a disc or tube of metal
is rotated at high speed and formed into an axially
symmetric part. Spinning can be performed by hand
or by a CNC lathe.
YoucaN
8. Hot spinning
Process:
A block is mounted in the drive section of lathe and
supported with tailstock. And the disk is attached with
head stock.
Spinning roller is attached with a T-rest lever bars.
It may suitable for both hot and cold working.
YoucaN
9. Hot working- Advantages
Lower working force is enough to give shape.
Very dramatic shape change is possible.
Properties such as strength, ductility and toughness is
improved.
Density increases by removing voids.
Desired shape can be easily obtained under plastic
deformation.
Effect of impurities can be reduced.
Good grain structure.
Atoms in same direction leads to better strength.
YoucaN
10. Hot working- disadvantages
Process takes place at higher temperature that Is above
7300 C, So special protection of machines is necessary
other wise machine and tool life is minimum.
Handling cost is high.
Automation is difficult one.
If the die or the tool wears the surface finish also
affects.
While the objects cools form its recrystallisation
temperature, due to shrinkage of the parts dimension
may vary.
YoucaN
11. COLD WORKING OF METALS
Plastic deformation of a metal to the required shape being performed
below the recrystallization temperature.
Process will work under room temperature.
RT – “Minimum temperature at which the complete recrystallization of
a metal takes place with in a specified time”
TYPES OF COLD WORKING PROCESS
- Drawing
- Squeezing
- Bending
12. Cold working- Materials
Low and medium carbon steels
Low alloy steels
Copper and light alloy such as aluminium,
magnesium, titanium.
YoucaN
13. 1.0 Drawing
- Blank Drawing
Cutting a flat shape from the metal.
-Tube Drawing
Tube piercing is called tube drawing
-Embossing
Process of making raised or projected design
on the surface of the metal.
-Wire Drawing
Diameter less than 16mm has drawn in the
form of wire coil.
-Metal Spinning
14. 2.0 Squeezing
- Coining
-Sizing
Size the metal to required shapes
-Swaging
It is used for producing rounded
components through radial impact forces
by reciprocating dies.
-Knurling
The rolls are pressed radially against the
rotating work piece, to make grip on the
handles.
15. 3.0 Bending
Bend into Desired shape like rods, wires, bars
- Plate Bending
Large Plates are bent to shapes
- Roll Forming
-It carries three rolls, Two are fixed and the third one is adjustable.
Diameter of all rolls are same.
- Angle Bending
Angles, Circles, Ovals
16. Cold working- Advantages
Widely applied as a forming process for steel.
Cold working is done at room temperature, so no
oxidation and scaling of work material occurs.
Excellent surface finish, which reduces the secondary
machining process.
High dimensional accuracy.
Highly suitable for mass production and automation,
because of low working temperature.
17. Cold working- Disadvantages
Strength of the metal is high, so large forces are needed
for deformation.
Complex shapes cannot be formed.
Tool must be specially designed, so high tool cost.
Stress formation in the metal during cold working is
higher. So this requires stress relieving.
YoucaN
18. Cold working- limitations
It depends on the Chemical composition (percentage of
carbon or alloying) of the material.
The maximum limit is usually 0.45% of carbon for steels in
cold extrusion &1.6% for cold forging.
Larger Grain size is easy for cold working.
YoucaN
19. Hot working Cold working
Working above recrystallization
temperature
Working below recrystallization
temperature
New crystals are formed New crystals are not formed
It hardens the metal No hardening
Impurities are removed from the metal Impurities are not removed from the
metal
Elongation of metal takes place Elongation decreases
Large size metals also deformed Limited to size
Internal stress is not formed Internal stress is formed.
YoucaN
20. FORGING PROCESSES
The desired shape is obtained by the application of a compressive force.
Types
1.0 Smith or Open die Forging
The forging is done in a heated work at the proper temperature by
placing on flat surface anvil through hammering the metal piece.
a) Hand Forging
b) Power Forging
24. TYPES OF FORGING MACHINES
1.0 Air and Steam Hammer
a) Air Hammer
It using air or steam.
- Single acting hammer – Air pressure is used to lift the ram only.
- Double acting hammer – Air pressure is used to lift the ram and
Impact the work piece.
25. 1.0 Air and Steam Hammer
b) Steam Hammer
It using air or steam.
- Single acting hammer – Air pressure is used for light work.
- Double acting hammer – Air pressure is used for heavy work.
26. 2.0 Mechanical Hammer
a) Helve Hammer
b) Trip Hammer
The reciprocating ram is the main part and it is toggle. The stroke length
various from 175 to 400blows/min.
27. 2.0 Mechanical Hammer
c) Level Spring Hammer
d) Pneumatic Hammer
An elastic rod is used to operate the ram. The stroke length various from 40
to 200blows/min.
28. TYPES OF FORGING OPERATIONS
1.0 Upsetting
The metal is heated at one end and the force is applied on the other
end by using hammer. The cross sectional area will increase and length will
decrease.
29. TYPES OF FORGING OPERATIONS
3.0 Punching
In this process, making of a hole in a
given job.
4.0 Bending
In this process, shapes like angles,
ovals and circle can be made.
2.0 Drawing Down
In this process, the cross
sectional area will decrease and length will
increase.
30. TYPES OF FORGING OPERATIONS
6.0 Forge Welding
Joining the work pieces by forging
operation.
7.0 Piercing
Making a blind or through holes with the help of a punch in the metal.
5.0 Cutting
Removal of excess metal from the work.
31. TYPES OF FORGING OPERATIONS
8.0 Swaging
Reducing or changing the cross sectional area of the metal.
9.0 Flattering
Used to flat the stock and that the stock is fitted properly in the closed die.
10.0 Fullering
Reducing the stock and increasing the length of the work piece by applying
pressure.
33. Forging operations
Upsetting:
The length is shortened and either or both its thickness
and width increased, the piece(stock) is said to be upset.
This operation is upsetting. Increase the cross sectional
area. (bolt manufacturing)
YoucaN
37. Forging operations
Fullering:
Reducing the cross section at the center plane and
increases its length.
This technique is commonly used to make the internal
combustion of engines.
YoucaN
38. Forging operations
Edging OR Rolling:
Distribute the metal longitudinally by moving metal
from the portion of higher cross section and increases
its length by compressive force.
YoucaN
39. Forging operations
Punching and blanking:
The most common shearing operations are punching-
where the sheared slug is scrap or may be used for
some other purpose-and blanking-where the slug is
the part to be used and the rest is scrap.
YoucaN
44. FORGING TOOLS
44
• TONGS :
Tongs are used mainly for
holding work of many
section.
• FLATTER :
Flatter is used to give
smoothness & accuracy to
articles which have already
been shaped by fullers and
swages.
• SWAGE :
Swage is used to
reduce/finish to round,
square/hexagonal form. It
consists of two parts-The top
part having a handle.
The bottom part having a
square shank.
45. 45
45
• ANVIL :
Anvil is used for supporting hot job
while hammering is done for shaping
it into various shapes. It is made of
cast steel.
• SWAGE BLOCK :
It is used for holding hot bars during
bending, support for punching holes
in a job & various holes.
• FULLERS :
Fullers are used for necking down/to
form depressions.
48. YoucaN
Defects of metal forged product include exterior cracking, interior
cracking, laps, cold shuts, warping of the part, improperly formed
sections and dead zones. Cracking both interior and exterior is caused by
excessive stress, or improper stress distribution as the part is being
formed. Cracking of a forging can be the result of poorly designed
forging die or excess material in the work piece. Cracks can also be
caused by disproportionate temperature distributions during the
manufacturing operation. High thermal gradients can cause cracks in a
forged part.
49. 1.) Unfilled Section:
As the name implies in this type of defect some of the forging
section remain unfilled. This is due to poor design of die or
poor forging technic. This is also due to less raw material or
poor heating.
This defect can be removed by proper die design, proper
availability of raw material and proper heating.
YoucaN
50. 2.) Cold Shut:
Cold shut includes small cracks at corners. These defects occur
due to improper design of forging die. It is also due to sharp
corner, and excessive chilling in forge product.
The fillet radius of the die should be increase to remove these
defects.
3.) Scale Pits:
Scale pits are due to improper cleaning of forged surface. This
defect generally associated with forging in open environment. It is
irregular deputations on the surface of forging.
It can be removed by proper cleaning of forged surface.
YoucaN
51. 4.) Die Shift:
Die shift is caused by misalignment of upper die and lower die.
When both these dies are not properly aligned the forged product
does not get proper dimensions.
This defect can be removed by proper alignment. It can be done by
provide half notch on upper die and half on lower die so at the
time of alignment, both these notches will matched.
5.) Flakes:
These are internal cracks occur due to improper cooling of forge
product. When the forge product cooled quickly, these cracks
generally occur which can reduced the strength of forge product.
This defect can be removed by proper cooling.
6.) Improper Grain Growth:
This defect occurs due to improper flow of metal in casting which
changes predefine grain structure of product.
It can be removed by proper die design
YoucaN
52. 7.) Incomplete Forging Penetration:
This defect arises due to incomplete forging. it is due to light or
rapid hammer blow.
This defect can be removed by proper control on forging press.
8.) Surface Cracking:
Surface cracking occurs due to exercise working on surfaces at low
temperature. In this defect, So many cracks arise on work piece.
This defect can be removed by proper control on working
temperature.
9.) Residual Stresses in Forging:
This defect occurs due to improper cooling of forged part. Too
much rapid cooling is main causes of this type of defects.
This can be removed by slow cooling of forged part.
YoucaN
53. Rolling
Rolling is the process in which the metals and alloys
are plastically deformed into semi finished or
finished condition by passing between circular
cylinders.
Due to the frictional forces the metal is drawn into the
opening.
Metal Changes its shape due to high compressive
forces.
Both hot(for drastic shape changing) and cold
rolling(for finishing) process are there.
From the start ingot- blooms- billet- slaps which are
further rolled into plat, sheet, rod, bar, pipe, rails.
YoucaN
58. Rolling mills classifications
Classifications based on number of rolls
Two high rolling mills
Three high rolling mills
Four high rolling mills
Multi roll rolling mills
Universal rolling mills
YoucaN
59. Two high rolling mills(single
direction)
Constant direction rolling
Upper rolls is moveable one to set the distance.
For single step reduction it is better one.
If successive reduction is need we have
to change the distance for each operations.
Least expensive
YoucaN
60. Two high rolling mills(both
direction)
For successive reduction this is better than single
direction rolling.
We can set a different distance for each direction.
Two high reversing mills are often used for the first rolling
of an ingot into blooms and slabs.
YoucaN
61. Three high rolling mills
Three rolls with constant direction
of rotation are arranged in a single vertical plane.
Lifting table used to rise or lower
the metal after each pass.
Both top and bottom rolls are driver rolls
YoucaN
62. Four high rolling mills
The bending of the roller is less if the diameter of the
roller is high. At the same time the power consumption
and force P value also very high for big diameter rollers.
To over come this problem small Diameter rollers with
larger diameter back up rollers are used. This can be
used for both directions.
YoucaN
63. Multiple roll mills
By reducing the work roll diameter will produce
bending effect on the back up rolls.
So in multiple roll mills a cluster of 6, 12, 20 rolls are
used to manufacturing strips. Form 0.001mm thick and
2000 mm wide.
YoucaN
In four high rolling the diameter of the back up rolls can
not be greater that 2 to 3 times that of the work rolls.
65. Universal rolling mill
Metal reduction occurs in both
horizontal and vertical rolls.
Vertical rolls are mounted either one side
or both sides
Horizontal rolls may be either two, three
or four high arrangement.
Used for roll wide strips, sheets, plates
and slabs that requires both rolling edges
and also for rolling of H sectioins.
YoucaN
70. Roll force
F= contact Length* width of strip * average ture stress
=L * w * True stress average
Power per roll
P= 2*3.14*Force* Length * speed in rpm / 6000
YoucaN
74. SHAPE ROLLING OPERATIONS
1.0 Ring rolling
A thick ring is expanded into a large diameter ring with a reduced cross
section. The ring is placed in between two rolls and one of the roll is driven , ring
thickness is reduced.
Advantages:
-Close tolerances
-Material Saving
- Short production times
75.
76. SHAPE ROLLING OPERATIONS
2.0 Thread rolling
Straight or tapered threads are formed. Threads are formed on the rod ,
with each stroke of a pair of flat reciprocating dies
Advantages:
-Surface finish
good
-Long life
- Thread strength
is good
77. DEFECTS IN ROLLED PARTS
1.0 Surface Defects
It includes scale, rust, cracks and pits due to impurities and inclusion
2.0 Internal Structural Defects
Strain on the material should adjust.
78.
79. DEFECTS IN ROLLED PARTS
3.0 Other Defects
a) Homogeneous deformation of element across the width
Due to decrease in thickness for the elements near the centre will be mainly converted
into increase in length and near the edge the decrease in thickness is converted into
lateral spread.
b) Homogeneous deformation in the thickness section
Due to reduction in height is converted into increase in length and the thickness of the
sheet does not undergo the same lateral deformation.
c) Folds
It is created during plate rolling if the reduction per pass is very small.
d) Lamination
Due to incomplete welding of pipe and blowholes during the rolling process the internal
defects such as fissures are created.
81. Drawing of wire, rod and tube
It is a cold working process in which the workpiece is
pulled through a tapered hole in a die so, the
diameter is reduced.
Wire can not be hot rolled economically smaller
than 5mm dia. So cold working is mainly used in wire
production
The starting material input for drawing is from the
extruded or rolled rods of 5 to 9mm.
Preparation of wire is important.(surface cleaning)
YoucaN
82. Wire drawing
The die geometry is typically a bell shaped one.
The land serves to guide the wire or rod as it comes out
of the working zone of the die.
Material below 16mm diameter are handled in coil
form.
The one end of the wire is gripped with a plier or
carriage which pulls the rod through all zones of the
die hole where it under goes deformation or
elongation. Then it is rolled on a power reel.
Then the power reel rotates at a proper speed and pulls
the wire.
Coil speed is 25m/s.
YoucaN
85. Rod drawing
Same as wire drawing process, here the product
must remain straight
The maximum length depends upon the carriage
movement distance
Here a moving chain arrangement is used to pull
the rod with a help of hook.
The pull capacity is 10kN to 1500kN.
Drawing speed may be
For larger size rod 0.15m/s
For smaller size rod 1.5m/s
YoucaN
91. EXTRUSION
Heated metal is compressed
and forced through a suitable
shaped die – Hot Extrusion.
Cold extrusion is non heated
metal but force is required
and used for commercial
metals.
95. Seamless tube manufacturing process
OR
Mannesmann cross roll piercing mill
OR
Rotary tube piercing
STEP 1: the billet piercing
STEP 2: the shell elongation
STEP 3: the tube sizing
STEP 4: the tube finishing
YoucaN
99. Seamless tube manufacturing
When a round bar is subjected to radial compressive forces,
stresses develop at the center of the bar.
When it is subjected continuously to these cyclic compressive
stresses, the bar begins to develop a small cavity at its center,
which then begins to grow.
The axes of the rolls are skewed in order to pull the round bar
through the rolls by the axial component of the rotary motion.
An internal mandrel assists the operation by expanding the
hole and sizing the inside diameter of the tube.
The mandrel may be held in place by a long rod, or it may be a
floating mandrel without a support.
Because of the severe deformation that the bar undergoes, the
material must be high in quality and free from defects (since
internal defects may propagate rapidly and cause premature
failure of the part during forming).
YoucaN