Metal forming processes
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This document summarizes several common metal forming processes. It discusses extrusion, which involves forcing metal through a die to reduce its cross-section. It also covers wire drawing, which reduces the cross-section of a metal rod by pulling it through successively smaller die holes. The document describes forging as shaping heated metal using compressive forces in dies or hammers. Rolling is defined as shaping metal by passing it through rotating rolls. Finally, casting and welding are summarized as processes for pouring molten metal into molds and joining metal pieces with heat respectively.
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Forging is a manufacturing process that shapes metal using force. It can be done hot or cold, with hot forging heating the metal above its recrystallization temperature for easier forming. Cold forging is done at room temperature but requires more powerful equipment. Forging processes fall into three categories: draw forming decreases width and increases length, upset forging increases width and decreases length, and compression forming provides multi-directional flow. Closed die forging uses molds attached to an anvil, while open die forging has no precut profiles. Press forging applies continuous compression pressure for prolonged contact with dies.
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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.
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This document discusses various types of forging processes including hot forging, press forging, swaging, and cold forging. It describes how each process uses compressive forces and dies to shape metal at different temperatures. Examples of specific forging techniques are provided like hammer forging, drop forging, and upset forging. The document also outlines common forging tools, defects that may occur, and applications in small tools and automotive manufacturing.
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Extrusion is a process where a billet is forced to flow through a die opening under high pressure to produce a part with a constant cross-section. Common materials extruded include metals like aluminum, copper, steel, and plastics. The extrusion process begins by heating the billet and placing it into an extrusion press where a ram pushes it through a die. Direct extrusion uses a stationary die and moving ram, while indirect extrusion has a movable die within a hollow ram. Extrusion can produce complex shapes and is used to manufacture parts like tubing, profiles, and frames.
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The document discusses various metal forming processes including forging processes like open die, closed die, and impression forging. It describes types of rolling processes and defects in rolled parts. It also covers principles of extrusion, types of extrusion, and tube drawing. Different metal forming techniques like forging, rolling, and extrusion are discussed along with their advantages in shaping metals and improving mechanical properties. Key terms related to forging like dies, forgings, and defects in forged parts are also summarized.
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BASIC MECHANICAL WORKING PROCESSES /METAL FORMING
IN THIS SECTION VARIOUS TYPE OF METAL FORMING PROCESSES HAS BEEN DISCUSSED AS WELL AS EFFECT OF VARIOUS VARIABLE ON METAL FORMING HAS BEEN DISCUSSED.
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1. Cold working is the plastic deformation of metals at a temperature below the recrystallization temperature, while hot working occurs above the recrystallization temperature.
2. Metal spinning is a metalworking process that forms an axially symmetric part by rotating a disc or tube of metal at high speed against a spinning roller. It can be done by hand or CNC lathe.
3. Forging processes like upsetting, heading, blocking, and fullering are used to refine the shape of metals for finishing. Punching and blanking are shearing processes used to produce holes.
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Here are the steps to determine the frequency of damped forced vibration of a spring mass system:
1. Set up the spring mass system ensuring the mass is attached properly to the spring.
2. Adjust the position of the mass so it is displaced from the equilibrium position. This will provide an initial disturbance.
3. Connect the system to the vibrator which will provide the external repeating force. Turn on the vibrator.
4. Observe the oscillations of the mass under the influence of both damping and external force. The amplitude will decrease gradually.
5. Use a stopwatch to measure the time period of several oscillations in the damped region.
6. Calculate the frequency as the reciprocal of
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Hot and cold working
1. Cold working is the plastic deformation of metals at a temperature below the recrystallization temperature, while hot working occurs above the recrystallization temperature.
2. Metal spinning is a metalworking process that forms an axially symmetric part by rotating a disc or tube of metal at high speed against a spinning roller. It can be done by hand or CNC lathe.
3. Forging processes like upsetting, heading, blocking, and fullering are used to refine the shape of metals for finishing. Punching and blanking are shearing processes used to produce holes.
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The document discusses the effects of temperature and strain rate on flow stress during metal forming. It states that flow stress decreases with increasing temperature above the recrystallization temperature, as recovery and recrystallization reduce strain hardening. Flow stress also decreases with decreasing strain rate. Typical strain rates used in different metal forming processes range from 10-8/sec for superplastic forming to 103/sec for cold working. The optimum conditions for superplasticity include a low strain rate, fine grain size, high temperature, and high strain rate sensitivity.
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Metal forming processes are used to shape metals into useful products. Rolling is the most common forming process and accounts for around 90% of metal forming. It involves passing metal between rolls to reduce thickness or change cross-section. Forging uses dies and compression to shape hot or cold metal. Extrusion forces heated metal through a die to create shapes like rods, tubes and structural sections. Drawing pulls metal through a die to make wires, rods and tubes from both hot and cold workpieces. Deep drawing specifically makes cylindrical parts like cups from sheet metal.
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1. Set up the spring mass system ensuring the mass is attached properly to the spring.
2. Adjust the position of the mass so it is displaced from the equilibrium position. This will provide an initial disturbance.
3. Connect the system to the vibrator which will provide the external repeating force. Turn on the vibrator.
4. Observe the oscillations of the mass under the influence of both damping and external force. The amplitude will decrease gradually.
5. Use a stopwatch to measure the time period of several oscillations in the damped region.
6. Calculate the frequency as the reciprocal of
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Hot chamber die casting machines are used for alloys with low melting temperatures like zinc, tin, or lead alloys. The molten metal is stored in a furnace attached to the machine. During injection, the molten metal is forced into the mold cavity under high pressure of 100-300 kp/cm2. This allows for a faster injection sequence than cold chamber machines and reduces burr formation and increases mold life.
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Centrifugal casting 1
- Centrifugal casting is a metal casting process that uses centrifugal force to form cylindrical parts by spinning a mold at high speeds. Molten metal is poured into the spinning mold and centrifugal force pushes the metal against the mold walls to form the casting shape.
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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.
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3. The document also discusses types of presses used for sheet metal working, including fly presses, power presses, gap presses, horn presses, and pillar presses.
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Metal forming processes
- 1. Metal forming processes BY Dr. K. SENTHILARASAN ASSISTANT PROFESSOR DEPARTMENT OF PHYSICS E.G.S.PILLAY ARTS & SCIENCE COLLEGE NAGAPATTINAM-611002
- 2. Metal forming processes • Extrusion • Wire drawing • Forging • Rolling • Casting • Welding
- 3. Extrusion • The process by which a piece of metal is reduced in cross section by forcing it to flow through a die force under high pressure is called extrusion. Thus it is similar to the squeezing of tooth paste from a collapsible tube. The building hardware’s, air crafts parts; structural shapes, rods and tubes are the important products from extrusion. There are two types of extrusion. • Direct extrusion: when the metal is squeezed through the die in the direction of the applied force then the process called direct extrusion. a heated cylindrical billet is placed into the die chamber and the dummy block and ram are placed into their proper positions. The metal is extruded through the die opening. • Indirect extrusion: when the metal emerges from the die in the opposite direction of the applied force the process is called indirect extraction. Ram or punch is hollow. Although indirect method reduces the friction between the billet and the wall of the container, the direct extrusion is used widely.
- 5. Advantage: • Desired shapes can be extruded with less cost. • The cost of dies is relatively low. • This involves more flexibility in design. Disadvantages: • Extruding speed is low. • Dimensional accuracy is not so good. • Surface layers of extruded metal undergo severs shear deformation
- 6. Wire drawing Wire drawing is the process in which a metal rod with larger cross section is pulled by means of a tensile force through successively smaller holes in a series of dies. Wire drawing is carried out on a hot rolled rod.
- 7. Forging: Forging is the shaping of the metal while it is in the heated plastic state by the application of localized compressive forces. The compressive forces may be exerted directly or through some die by a hammer, a press or an upsetting machine, etc.
- 8. Forging operations • Upsetting: the thickness or the cross section is increased at the expense of its length. This operation is carried out by heating the bar and applying pressure at the ends. • Drawing down: The length of the bar is increased at the expense of its cross section. • Setting down: Thinning down by the repeated strokes of a hammer. • Bending: angle bends are made by hammering the bar over the edge of the anvil or over a vise jaw itself while the bar being securely held. • Punching and drifting: punching is the operation of creating holes in the forgings while in the heated plastic state. Drifting is enlarging of existing holes in the forgings.
- 10. Forging processes: • Open die forging • Closed die forging Advantages of forging: • There is an improvement in resistance to shock and vibrations. • It is quick process. Time and power are saved. • Percentage of elongation is also more. • Impurities are broken into fragments and that are uniformly dispersed.
- 11. Rolling Rolling is the shaping the metal by passing it between pairs of rotating rolls. Rolling is conducted either as a cold working or as a hot working when the work piece is passed between the rotating rolls; it is plastically deformed due to high compressive stresses from the squeezing action of the rolls.
- 12. Casting: Casting is the process of pouring molten metal into a mould and allowing it to solidify. • Sand casting • Shell mould casting • Plaster mould casting • Die casting • Centrifugal casting. Sand casting is widely adopted for very large or heavy casting. The die casting is done by forcing the molten metal into a metal die by pressure. Centrifugal casting is done by rotating a mould while the molten metal solidifies so as to utilize centrifugal forces to position the metal in the mould.
- 13. • Welding: The process of uniting two pieces of metal by means of heat by bringing their ends to the plastic or molten state is known as welding. Welding processes • Fusion welding • Pressure welding Fusion welding: • Oxy-acetylene welding • Metallic welding • Argon arc welding • Carbon welding • Atomic hydrogen welding • Thermal welding
- 14. Pressure welding: • Blacksmith forge welding • Electrical resistance welding • Spot welding • Seam welding • Butt welding • Flash welding • Projection welding • Percussion welding
- 15. THANK YOU